Process Design Engineer

Decatur, AL

The Process Design Engineer will be responsible for scoping, designing and following the execution, and commissioning phases for projects that add capabilities, improve quality, or increase production capacity. The role is focused on finding creative solutions to challenges, providing rapid implementation timetables while achieving the best alignment with customer and business needs at lowest cost.

The role will focus on:

Integration as part of a project team with project leaders, manufacturing staff and Technology engineers.

Develop flow schemes to determine mass and energy balances, control logic, and equipment specifications.

Model processes as part of the overall sizing/design processes.

Continued involvement in project execution and start up beyond the design phase.

Interacting with leading internal and external experts, vendors, and other outside consultants to develop and implement improvements

Providing technical guidance on areas of expertise to plant manufacturing and engineering organizations.

Performing process HAZOP’s, RCA’s, FMEA’s, and PSR’s

Essential Functions:

Manage and maintain key capacity of conventional nylon polymerization or chemical intermediates manufacturing processes by:

Developing projects for low cost routes to debottleneck capacity

Maximizing throughput rate at equivalent quality

Optimizing operation for conversion costs

Extensive experience using process modeling software (e.g. Hysys or ASPEN) to design process equipment including reactors, heat exchangers, pumps, compressor and other process equipment.

Proactively manage project milestone delivery, identify potential obstacles and issues, devise contingency plans, and engage stakeholders at necessary decision points

Oversee development of process flow diagrams, heat & mass balances, piping & instrument diagrams, and economic estimates from initial concept to final design

Manage the project stage gate process with Six Sigma rigor and statistical methodology and use tools to drive efficiency across all programs

Manage internal resources, vendors, consultants, and contract resources to accomplish project goals

Maintain product and company reputation by complying with federal and state regulations

Maintain safe and clean working environment by enforcing procedures, rules, and regulations

Monitor work for compliance to applicable codes and accepted engineering practices and standards

Required Skills:

Bachelor’s degree in Chemical Engineering. Advanced degree considered a plus.

5 + years Process Design experience

Process Simulation REQUIRED


Ability to interface, orally and in writing, with many levels of employees of various disciplines within various departments and all other internal and external contacts.

Strong analytical and technical skills, ability to solve complex problems, ability to innovate, and a strategic business perspective.

Ability to work with interdisciplinary and cross-functional teams to take a concept to plant implementation.

Broad knowledge of chemical unit operations including reactions, separations, environmental controls and so forth. Knowledge of computer systems and software related to process control, optimization and simulation.

Senior experience with Aspen, {HYSYS, MUST HAVE} Fathom, HTRI, AFT Arrow, Process Explorer, Provox, AIM Station, DMACS, or similar packages is needed.

This job may require occasional travel for vendor visits and internal meetings. Travel may be domestic or foreign.


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