Process Engineer/ Senior Process Engineer

This role involves providing hands-on process engineering support, technical audits, and manufacturing assistance to ensure safe, reliable, and efficient plant operations. The position focuses on troubleshooting, process optimization, product quality improvement, safe plant modifications, and cost reduction. It requires close coordination with licensors and vendors, as well as the preparation of technical and financial stewardship reports to support operational excellence.

Key Responsibilities

Plant Monitoring and Troubleshooting:
Continuously monitor operating indices, conduct technical audits, and investigate process upsets and quality deviations. Recommend corrective actions to address safety, efficiency, and reliability gaps.

Reactors and Furnaces:
Evaluate and optimize the performance of furnaces and reactors, including fluidized-bed reactors and oxidation processes. Monitor catalyst activity, conversion rates, selectivity, heat transfer, and energy efficiency to enhance overall process performance.

Separation Processes:
Oversee and optimize distillation/rectification columns, liquid-liquid extraction, and concentration systems. Focus on improving separation efficiency, product recovery, product quality, and reducing operating costs.

Engineering Studies:
Conduct heat and material balances, process simulations, hydraulic studies, and equipment evaluations for reactors, columns, heat exchangers, pumps, compressors, and related utilities.

Cost and Energy Management:
Track consumption of raw materials, catalysts, chemicals, and utilities. Maintain production and energy balances, reconcile consumption data, and identify opportunities to reduce variable costs and minimize process losses.

Plant Modifications and CAPEX:
Identify projects aimed at improving safety, reliability, and capacity (debottlenecking). Develop feasibility studies, business cases, and technical scopes. Support project implementation and performance verification.

Process Safety:
Support Management of Change (MOC), HAZOP/PHA, risk assessments, and Pre-Startup Safety Reviews (PSSR). Review process safeguards, chemical compatibility, and operating limits to mitigate reaction hazards and other safety risks.

Engineering Documentation:
Maintain up-to-date Process Safety Information (PSI), Process Flow Diagrams (PFDs), Piping and Instrumentation Diagrams (P&IDs), equipment specifications, and control philosophies. Ensure all modifications comply with relevant codes, standards, and licensor requirements.

Technical Coordination:
Collaborate with Operations, Maintenance, Engineering, and Laboratory teams. Liaise with licensors and vendors, evaluate technical proposals, and support plant turnarounds, commissioning, startups, and shutdowns.

Planning and Reporting:
Prepare daily monitoring, performance, and stewardship reports. Assist with production planning, budgeting, forecasting, month-end reconciliation, and timely updates in SAP. Escalate technical issues to management as needed.

Required Qualifications

- Bachelor’s degree in Chemical Engineering.
- 3 to 8 years of relevant process engineering experience in oil and gas, refinery, petrochemical, fertilizer, or chemical manufacturing environments.
- Practical experience with furnaces, fluidized-bed reactors, distillation/rectification columns, oxidation reactions, or liquid-liquid extraction processes.
- Proficiency in hands-on process calculations and troubleshooting.
- Skilled in Aspen HYSYS, with working knowledge of Aspen EDR, KORF, KG-TOWER, PIPEFLOW, or equivalent engineering software.
- Strong analytical skills, attention to detail, clear communication abilities, teamwork orientation, and ethical professional conduct.

Preferred Qualifications and Benefits

While not explicitly stated, candidates with additional experience in process safety management, project execution, and cross-functional coordination will be well-positioned for success in this role. The position offers the opportunity to contribute to critical plant operations and continuous improvement initiatives in a dynamic industrial setting.