Process Engineer

Job Summary:

The Process Engineer plays a critical role in optimizing, designing, and maintaining the continuous production processes used in petrochemical manufacturing. The engineer ensures that plant operations are safe, efficient, cost-effective, and environmentally compliant. This position involves troubleshooting plant performance issues, implementing process improvements, and supporting capital projects to enhance production capability and reliability.

Key Responsibilities:

1. Process Optimization & Performance Monitoring

• Monitor daily plant operations and key performance indicators (KPIs) to ensure process stability and efficiency.
• Analyze process data and trends to identify performance gaps and recommend corrective actions.
• Optimize energy and raw material utilization to reduce costs and environmental impact.
• Develop and update process simulations, heat and material balances, and process flow diagrams (PFDs).

2. Troubleshooting & Technical Support

• Provide on-site technical support to operations for process-related issues.
• Conduct root cause analyses (RCA) for upsets, quality deviations, and equipment failures.
• Work closely with maintenance, production, and safety teams to resolve process bottlenecks and enhance reliability.

3. Process Design & Project Support

• Participate in process design, modification, and scale-up of new and existing units.
• Develop and review Piping & Instrumentation Diagrams (P&IDs) and control strategies.
• Support capital projects from concept through commissioning and start-up.
• Prepare technical documentation, cost estimates, and feasibility studies for improvement projects.

4. Safety, Health & Environment (SHE)

• Ensure all process operations comply with HSE regulations, company policies, and Process Safety Management (PSM) requirements.
• Conduct hazard analyses (HAZOP, HAZID, LOPA) and implement mitigation measures.
• Participate in safety audits, risk assessments, and incident investigations.

5. Continuous Improvement

• Lead Lean Six Sigma or continuous improvement initiatives focused on yield, throughput, and reliability enhancement.
• Implement advanced process control (APC) strategies and digitalization initiatives where applicable.
• Train and mentor plant operators and junior engineers on process optimization and safety awareness.

Qualifications:

Education:

• Bachelor’s degree in Chemical Engineering or related field (Mechanical Engineering with process experience may be considered).
• Master’s degree in Process Engineering or Chemical Engineering is an advantage.

Experience:

• +10 years of experience as a Process Engineer in petrochemical, refining, or chemical manufacturing environment.
• Strong background in distillation, heat exchange, reactor systems, and separation processes.
• Experience with process simulation tools such as Aspen HYSYS, Aspen Plus, PRO/II, or CHEMCAD.
• Familiarity with API, ASME, OSHA, and EPA standards and practices.

Skills & Competencies:

• Excellent analytical and problem-solving skills.
• Strong understanding of thermodynamics, fluid dynamics, and process control systems.
• Effective communication, teamwork, and project management skills.
• Proficiency in data analysis and performance monitoring software (e.g., PI ProcessBook, Excel, Power BI).
• Knowledge of Process Safety Management (PSM) and environmental compliance standards.