Sr Process Design Engineer

About the role

The Senior Process Design Engineer will have direct responsibility for the Process Engineering function as it relates to capital projects. The individual will direct, coordinate, and exercise functional authority for planning, organization, control, integration, and completion of process scopes and related documents within the area of assigned responsibility. This role requires a thorough understanding of process equipment design—including pumps, heat exchangers, vessels, etc.—and the ability to apply process tools to design piping systems, complete material and energy balances, and perform process optimization studies. The position reports directly to the Americas North Design Engineering Lead and can be based at Grace Headquarters in Columbia, Maryland or in the Great Lakes Region. Nearest major market: Baltimore.

Responsibilities

• Evaluates and approves process design changes and specifications.
• Develops, in collaboration with Process Technology, Business Units, and Operations, a standard Basis of Design (BOD) package that includes Scope of Work, PFDs, P&IDs, and material balances.
• Develops front‑end packages.
• Creates equipment and services bid documentation, reviews vendor quotations, and issues procurement recommendations.
• Evaluates and approves design changes, specifications, and drawing releases.
• Evaluates EH&S design requirements and ensures adherence to corporate policies.
• Participates as the engineering representative in Process Hazard Analyses (PHA) and HAZOP studies.
• Supports start‑up activities from a process engineering perspective.
• Prioritizes workloads and effectively manages third‑party engineering teams to execute assigned tasks.
• Ensures firm understanding and compliance with the Grace Project Methodology (GPM) process.

Physical Requirements and Environment

• Must be able to stand, walk, sit, climb, balance, stoop, kneel, crouch, crawl, and climb stairs and ladders over 100 ft.
• Must be willing to wear PPE (hard hat, protective eyewear, steel‑toed boots, hearing protection, Level A suit, full‑face respirator, etc.).
• Ability to work in a high‑hazard environment, including adverse weather conditions, elevated spaces, confined spaces, extreme temperatures, and noisy surroundings.
• Ability to follow safety protocols and standards while working in a pilot‑plant facility with highly hazardous materials.

Required Qualifications

• BS degree in Chemical Engineering, Mechanical Engineering, or a related field.
• 10+ years of experience in chemical, petrochemical, specialty chemical, refining, pharmaceutical, or related manufacturing industries.
• Experience in process design and process engineering within the chemical industry.
• Proven ability to execute front‑end design for capital projects.
• Experience overseeing chemical‑industry contractor deliverables.
• Up to 25 % travel, including international, may be required.
• Authorization to work in the United States without employer‑sponsored work authorization (no visa sponsorship).

Preferred Qualifications

• Professional Engineer (PE) license.
• Experience in catalyst manufacturing, specialty chemicals, petrochemicals, refining, or material‑science industries.
• Experience with process scale‑up, pilot‑plant operations, and commercialization of new technologies.
• Familiarity with environmental compliance requirements and sustainability initiatives.
• Experience leading global or multi‑site engineering projects.
• Knowledge of process simulation software such as Aspen Plus, Aspen HYSYS, CHEMCAD, or equivalent.
• Strong oral and written communication skills and ability to work effectively in a team environment.
• Demonstrated ability to network effectively within the business unit and with external stakeholders.
• Very good understanding or working knowledge of Grace’s process technology, unit operations, and related operations experience.
• Knowledge of Grace’s internal IPs and applicable industry codes and standards.

Benefits

• Medical, dental, and vision insurance.
• Life insurance and disability coverage.
• Grace Wellness Program.
• Flexible workplace arrangements.
• Retirement plans with 401(k) company match.
• Paid vacation and holidays.
• Parental leave.
• Tuition reimbursement.
• Company donation match program.