Maximizing Industrial Efficiency Through Process Simulation & Automation
Hi, I'm Eng. Andrew Omwenga — a Chemical Engineer empowering industrial plants to enhance operational performance by designing energy-efficient process models that cut fuel penalties, lower operating costs, and advance carbon capture, while upskilling engineering teams through Aspen HYSYS & Python automation.
Who I Am
I am Eng. Andrew Omwenga, a Chemical Engineer and founder of Chem Eng Lab with over 3 years of experience in industrial process modeling. I empower manufacturing and process facilities to enhance operational performance through rigorous energy-efficient modeling and software automation that cuts fuel costs and optimizes plant throughput.
Since graduating, I have spearheaded complex industrial research and consulting projects across East and Southern Africa — from seawater desalination and edible oil processing to international boiler energy modeling.
Modeled thermal & adsorption energy integration for a coastal seawater desalination system using hybrid Multi-Effect Distillation with Adsorption Desalination (MED-AD).
Process modeling for solvent extraction, degumming, and heat recovery in edible sunflower oil processing.
Developed a predictive model analyzing steam boiler energy efficiency and predicting optimal preventive maintenance windows to prevent costly thermal shutdowns.
WHAT I OFFER
Process Optimization Services
Helping process industries identify losses, optimize operations, and turn plant data into actionable engineering decisions.
Industrial Energy & Process Performance Diagnostics
Find where your plant is losing energy and process performance. I analyze plant operating, production and utility data to identify abnormal energy consumption, process inefficiencies and production-performance losses — converting operational data into engineering KPIs and prioritizing improvement opportunities.
“Know where performance is being lost — and what to investigate first.”
Steam & Thermal System Optimization
Reduce avoidable thermal-energy losses across your process. I evaluate boilers, steam distribution, process heating, heat exchangers and condensate systems to identify thermal inefficiencies and opportunities for improved heat recovery and energy utilization.
“Turn fuel and steam consumption into measurable process-performance improvements.”
Process Data Analytics & Optimization
Turn operating data into better process decisions. I combine chemical engineering principles, process modelling and data analytics to understand how operating variables affect energy, yield and equipment performance — then identify better operating strategies.
“Move from monitoring what happened to understanding why — and what to change.”
Have plant data but not sure where the losses are?
Let's identify the process area worth investigating first.
Relevant across food & beverage, agro-processing, chemicals, water, bioprocessing and other process industries.
Choose Your Engagement Pathway
Tailored process engineering solutions for industrial facilities and hands-on simulation masterclasses for engineers.
Consulting & Simulation Services
High-ROI engineering modeling, thermodynamic verification, and automated predictive tools to maximize plant efficiency and lower operating costs.
Identify furnace duty penalties, model shell-and-tube fouling rates, and optimize heat exchanger cleaning schedules.
Rate-based chemical absorption modeling in Aspen Plus for 98%+ CO2 recovery with reboiler energy minimization.
I connect Aspen HYSYS flowsheets with Python to automate sensitivity studies, creating predictive tools that reduce manual engineering hours and optimize plant performance.
The Training Lab
Structured live online cohorts led by Eng. Andrew Omwenga, featuring hands-on Aspen flowsheet files and Python automation workshops.
Master fluid package selection, material/energy streams, heat exchangers, and distillation columns from scratch.
Crude assay characterization, atmospheric CDU modeling, and preheat train fouling analysis on real refinery cases.
Learn to write Python COM automation scripts to drive Aspen HYSYS flowsheets and solve thermodynamic equations.
Industries I Serve
Continuous simulation, energy audit & process debottlenecking across heavy process plants
Oil Refining & Petrochemicals
Crude preheat train fouling analytics, atmospheric CDU column optimization & furnace penalty reduction.
Food Processing, Edible Oils & Bakeries
Predictive boiler efficiency modeling, edible oil solvent extraction & industrial bakery energy recovery.
Clean Energy & Carbon Capture
Rate-based MEA chemical absorption, green hydrogen DRI ironmaking & industrial decarbonization roadmaps.
Thermal Desalination & Coastal Utilities
Multi-Effect Distillation (MED-AD) seawater desalination modeling powered by plant waste heat.
Oil Refining & Petrochemicals
Crude preheat train fouling analytics, atmospheric CDU column optimization & furnace penalty reduction.
Food Processing, Edible Oils & Bakeries
Predictive boiler efficiency modeling, edible oil solvent extraction & industrial bakery energy recovery.
Clean Energy & Carbon Capture
Rate-based MEA chemical absorption, green hydrogen DRI ironmaking & industrial decarbonization roadmaps.
Thermal Desalination & Coastal Utilities
Multi-Effect Distillation (MED-AD) seawater desalination modeling powered by plant waste heat.
Process Simulation Video Tutorials & Project Walkthroughs
Watch step-by-step Aspen HYSYS, Aspen Plus, Aspen EDR, and Python automation tutorials on pipeline hydraulics, heat exchanger rating, cumene distillation, and carbon capture.
Featured Case Studies
Crude Preheat Exchanger Fouling
Preheat fouling forced furnace duty up +29.2%, spiking fuel costs.
Aspen HYSYS steady-state model coupled with Python COM sensitivity solver.
Identified $786,240 annual fuel penalty, establishing dynamic cleaning schedules.
MEA Carbon Capture System
Dilute flue gas CO2 emissions requires energy-intensive solvent regeneration.
Rate-based MEA absorption model with rich/lean heat integration in Aspen Plus.
98.25% recovery achieved while cutting stripper reboiler duty by 14.5%.
Refinery Pinch Energy Network
Sub-optimal cross-stream heat recovery inflated fired heater natural gas usage.
Pinch analysis retrofit adding two shell-and-tube exchangers in series.
Avoided 13.8 GJ/h in furnace duty, yielding $662,400/yr annual savings.
Proven Operational Impact
What plant managers, carbon capture specialists, and simulation trainees say about working with Eng. Andrew Omwenga.
“Andrew's preheat exchanger fouling model identified a $786,000 annual fuel penalty in our CDU fired heater. That single study transformed our cleaning cycle schedule.”
“Outstanding rate-based MEA carbon capture simulation rigor in Aspen Plus. Andrew reduced our pilot plant reboiler duty target by 14.5% through rich/lean heat integration.”
“Andrew Omwenga's Python for Chemical Engineers course taught me how to automate Aspen HYSYS via Win32 COM. Practical, hands-on engineering skills I use every day.”
Ready to Optimize Your Plant or Upskill Your Team?
Whether you need a custom refinery simulation study or live Aspen & Python training led by Eng. Andrew Omwenga.