Senior Process Engineer

About the role

We are seeking a highly skilled and motivated Senior Process Engineer to join our Technology Team. This position serves as a critical technical resource bridging the Technology Team's process design capabilities with the operational needs of our Sulfuric Acid and Spent Acid Regeneration (SAR) manufacturing network. The successful candidate will be an experienced chemical engineer with a deep passion for process design, rigorous technical problem-solving, and a proven ability to drive projects from concept through execution.

Responsibilities

• Process Design & Engineering
  • Lead the development of process designs for new capital projects, technology upgrades, and plant modifications — from conceptual through detailed design phases, including PFDs, P&IDs, mass and energy balances, equipment sizing, and process specifications.
  • Develop and maintain rigorous process simulations using Aspen Plus and/or Aspen HYSYS to support design, optimization, and troubleshooting activities.
  • Author and review engineering deliverables including process design packages, basis of design documents, equipment datasheets, and design philosophies.
  • Evaluate process technology alternatives and provide documented recommendations to support investment decisions.
  • Initiate and manage Management of Change (MOC) documentation; participate in PHAs/HAZOPs and support PSSRs for new and modified processes.
• Project Scoping & Execution
  • Define project scope, develop cost estimates, and prepare capital appropriation requests for process improvement and capacity projects.
  • Develop and validate technical justifications including ROI analyses, safety cases, and environmental impact assessments.
  • Interface with multidisciplinary project teams (mechanical, electrical, instrumentation, civil) as the process engineering lead throughout project execution.
  • Monitor and report on process engineering deliverable progress relative to project schedules and budgets.
• Technology Development & Knowledge Management
  • Contribute to the Technology Team's body of knowledge for sulfuric acid and SAR technologies — documenting design standards and lessons learned.
  • Identify emerging process innovations applicable to the business; support pilot testing and scale-up evaluations.
  • Mentor and provide technical guidance to junior process engineers and plant technical staff.
• Plant Technical Support & Troubleshooting
  • Serve as a technical resource for plant operations teams at UPA and SPPC Spent Acid sites.
  • Conduct in-depth technical troubleshooting of sulfuric acid and spent acid regeneration process upsets, performance gaps, and reliability issues.
  • Perform root cause analyses (RCA) on process failures and deviations; develop and track corrective and preventive actions.
  • Analyze plant operating data to identify performance trends, debottlenecking opportunities, and efficiency improvements.
  • Support operational readiness activities including development of SOPs, operator training materials, and startup/shutdown procedures.

Qualifications

• B.S. in Chemical Engineering required
• 7–10+ years of progressive process engineering experience in chemical, petrochemical, or specialty chemical manufacturing
• Demonstrated experience in process design — PFDs, P&IDs, mass and energy balances, and equipment specifications
• Prominent ability to scope and lead engineering projects from concept through implementation
• Strong technical troubleshooting skills with the ability to diagnose complex process issues and drive resolution
• Excellent written and verbal communication skills for technical and non-technical audiences
• Ability and willingness to travel to plant sites as needed (estimated 20–40%)

Preferred Qualifications

• Sulfuric acid plant experience (contact process, double absorption, SO₂ handling, converter operations, acid towers/absorbers) — strongly preferred
• Spent acid regeneration (SAR) process experience — a significant plus
• Proficiency in Aspen Plus and/or Aspen HYSYS — strongly preferred
• Experience with HAZOP/PHA facilitation and MOC processes
• Capital project development experience (AACE cost classes, FEED studies, project scoping)
• Prior experience in a technology center, R&D, or corporate engineering function is desirable