Looking for a job

Aayush Karna

@aayushkarna1

Message

I build simulation and optimisation models that advance low-carbon thermal and industrial energy systems.

France

Message

What I'm looking for

I'm interested in simulation engineering, process modelling, thermal and energy systems, computational engineering, and R&D opportunities.

At ArcelorMittal R&D, I developed a dynamic co-simulation framework for a MIDREX direct reduction plant, connecting a MATLAB transient shaft-furnace model and industrial gas-circuit model through Python.

I used the plant-level model to assess hydrogen-injection decarbonisation strategies, including their effects on natural-gas consumption, CO₂ emissions, and techno-economic feasibility.

At NYU Abu Dhabi, I optimised micro-Tesla valves with CFD, delivering a threefold improvement in diodicity and presenting the work at ASME FEDSM 2024. I also built machine-learning surrogate models for rapid heat-exchanger design exploration.

I'm a thermal energy engineer with an Erasmus Mundus master's in Decentralised Smart Energy Systems and a mechanical engineering background, focused on process modelling, CFD, optimisation, and energy-system analysis.

Experience

Work history, roles, and key accomplishments

Process Modelling Intern (Master's Thesis)

ArcelorMittal

Mar 2026 - Aug 2026 (5 months)

• Developed a plant-level dynamic co-simulation framework for a MIDREX direct reduction plant, coupling a MATLAB-based transient shaft furnace model with an industrial process simulation gas circuit model through a Python interface.

Tamayyuz (Excellence) Research Fellow – Thermal Optics and BioPhotonics Laborato

New York University Abu Dhabi

Sep 2023 - Aug 2024 (11 months)

• Conducted CFD-based design optimization of micro-Tesla valves (single- and multi-stage), achieving a threefold enhancement in diodicity (valve's effectiveness), and validated performance using Newtonian and non-Newtonian fluid models.
• Developed surrogate models using artificial neural networks and optimization algorithms to predict heat exchanger geometries from target performance and design c

Research Assistant - Applied Computational Engineering Lab

New York University Abu Dhabi

May 2023 - Jul 2023 (2 months)

• Benchmarked FLOW-3D CAST against ANSYS Fluent for investment casting simulations of triply periodic minimal surface (TPMS) structures, analyzing porosity formation, thermal residual stresses, solver scalability, and defect-prediction capabilities to guide tool-selection decisions for advanced manufacturing workflows.

Mechanical Engineering Intern

Tribhuvan International Airport

Jul 2022 - Aug 2022 (1 month)

• Completed a rotational internship across HVAC, electromechanical, terminal facilities, and fire safety divisions, supporting maintenance of critical airport infrastructure.

Research Assistant — Laboratory for Advanced Neuroengineering and Translational

New York University Abu Dhabi

Feb 2021 - Dec 2021 (10 months)

• Upcycled polyethylene and polypropylene waste into carbon quantum dots and tested their applicability in bioimaging.
• Developed a novel probe that enables early diagnosis of Alzheimer’s disease using silicon quantum dots.
• Characterized the quantum dots using optical absorption and photoluminescence spectroscopy.

Education

Degrees, certifications, and relevant coursework

St. Xavier's College, Maitighar

CIE A-Levels, Physics, Chemistry, Mathematics and Biology

Universitat Politècnica de Catalunya

Erasmus Mundus Master in Decentralised Smart Energy Systems, Thermal Energy Engineering Specialization

2025 - 2026

Thesis: Physical Modelling of the Direct Reduced Iron (DRI) Process – dynamic plant-level modelling of a MIDREX plant to evaluate hydrogen-injection decarbonisation strategies, conducted at ArcelorMittal R&D.

Universite de Lorraine

Master Energie parcours, Decentralised Smart Energy System

2024 - 2026

Key Projects:
• Green Building Analysis – Designed an energy-efficient HVAC system for an office building in Terrassa, Spain, integrating adaptive control and passive facades to cut annual cooling demand by 59%.
• Decarbonizing Aviation – Evaluated algae-based biofuel pathways (HEFA, Fischer-Tropsch, ATJ) for sustainable aviation fuel, identifying HEFA as lowest-emission at 32.6 gCO₂e/MJ.