Senior Process Engineer

Senior Process Engineer – Cryogenic NGL Recovery Specialist

Company: Melland Engineering & Consulting
Location: Houston, TX (In Office, 25% travel to West Texas required)
Employment Type: Full-Time
Experience Level: 5-10 years
Salary: Commensurate with Experience

We are seeking a Senior Process Engineer with deep, hands-on experience in Cryogenic NGL recovery and natural gas processing facilities
. This role requires strong operational and engineering expertise in cryogenic gas plants, with ownership of troubleshooting, optimization, and debottlenecking of NGL recovery systems.

The ideal candidate will act as a technical authority for cryogenic gas processing performance
, driving improvements in recovery efficiency, reliability, and plant throughput.

• Direct experience with Cryogenic NGL recovery plants (required)
• Strong background in natural gas processing, turboexpander systems, or cryogenic gas fractionation
• Proven experience in plant troubleshooting, optimization, and debottlenecking
• Hands-on experience with Aspen HYSYS and/or Uni Sim
• Strong understanding of:
  • Heat & material balances
  • Refrigeration cycles
  • Gas separation processes

• Develop and validate process deliverables including:
  • PFDs and P&IDs
  • Heat & material balances
  • Hydraulic and equipment sizing calculations
  • Process datasheets and operating cases
• Perform process simulation and performance modeling using Aspen HYSYS / Uni Sim
• Analyze cryogenic system behavior including turboexpander and JT valve performance
• Lead troubleshooting of cryogenic NGL recovery units and gas processing facilities
• Identify opportunities to improve:
  • NGL recovery efficiency
  • Plant throughput and reliability
  • Energy and refrigeration system performance
• Support commissioning, startup, and stabilization of cryogenic plants
• Work directly with operations to resolve performance issues in real time

• Serve as technical authority for cryogenic process design and plant performance
• Review engineering deliverables for accuracy, operability, and process integrity
• Provide technical guidance to junior engineers and multidisciplinary teams
• Ensure process design intent is maintained across engineering disciplines

• Manage multiple complex cryogenic and gas processing projects simultaneously
• Coordinate across mechanical, instrumentation, and operations teams
• Ensure alignment of scope, schedule, cost, and technical objectives
• Communicate with project managers, clients, and field operations teams

• Apply and improve engineering standards for gas processing and cryogenic systems
• Ensure compliance with engineering codes and company quality systems
• Drive continuous improvement initiatives focused on plant performance
• Communicate technical findings and recommendations to leadership

• Interface directly with clients and operating teams to understand plant constraints
• Translate operational issues into engineering solutions
• Support business development and technical discussions when required

• Senior-level process engineer with strong cryogenic gas plant experience
• Strong field exposure in gas processing operations
• Skilled in troubleshooting and improving live plant performance
• Comfortable bridging operations and engineering teams
• Strong communicator with operators, engineers, and clients

• Competitive salary based on experience and qualifications.
• Comprehensive benefits package, including health, dental, and vision insurance, 401(k), and paid time off.
• Opportunities for professional growth and development in the natural gas industry.
• A collaborative and innovative work environment with exposure to cutting-edge projects.
• Support for new graduates through mentorship and hands-on training.

Melland Engineering & Consulting is an equal opportunity employer.