Senior Process Engineer

Job Title:

Senior Process Engineer Job Description

The Senior Process Engineer leads the design, commissioning, and operation of hazardous materials production plants, with a strong focus on chemical process engineering fundamentals and hands‑on plant experience. This role develops process designs and control strategies, oversees pilot plant operations, mentors junior engineers, and supports fast‑paced projects that contribute to critical national programs. The position requires frequent travel to a project site in Texas and close collaboration with a small, cross‑functional engineering team based in Littleton, Colorado.

• Serve as the project lead for production plant design and commissioning, guiding projects from concept through start‑up.
• Travel to the project site in Texas approximately 50% of the time to support design reviews, commissioning, and on‑site problem solving.
• Develop detailed engineering diagrams, including process and instrumentation diagrams (P&IDs), to define process flows and control strategies.
• Create process equipment specifications and data sheets to support procurement and installation of process equipment.
• Develop process instrumentation and control strategies in coordination with automation and controls engineers.
• Coordinate with automation and advanced process monitoring teams to integrate process control systems into batch and continuous flow operations.
• Lead and oversee pilot plant commissioning activities, including planning and executing test production runs.
• Monitor and guide pilot plant operations to validate process performance and support scale‑up to full production.
• Review and oversee process deliverables prepared by junior engineers, providing mentorship, feedback, and technical guidance.
• Ensure that engineering deliverables are completed accurately and on schedule, supporting overall project timelines and milestones.
• Perform project engineering tasks such as writing technical reports, preparing documentation, and delivering technical presentations to internal and external stakeholders.
• Apply strong chemical engineering fundamentals to solve complex process problems in hazardous materials and chemical manufacturing environments.
• Handle hazardous and energetic materials with strict adherence to safety processes, procedures, and regulatory requirements.
• Support company compliance with restricted information security regulations by following established protocols and documentation practices.
• Contribute to modular plant design efforts and support both batch and continuous flow processing projects.
• Collaborate closely with a cross‑functional team in a fast‑paced, high‑accountability environment to deliver high‑quality engineering solutions.
• Demonstrate superior attention to detail in all aspects of design, documentation, and plant operations.
• Communicate effectively with team members and stakeholders through clear verbal communication and well‑structured written reports.

• Proven experience in process engineering, plant design, and batch processing operations.
• Hands‑on experience with hazardous material processing or manufacturing in areas such as energetic materials, explosives, pharmaceuticals, petroleum, or similar industries.
• Strong chemical engineering fundamentals combined with practical, hands‑on plant experience.
• Demonstrated ability to lead the design and commissioning of hazardous materials production plants.
• Proficiency in developing P&IDs, equipment specifications, and process control strategies.
• Experience integrating automation and advanced process monitoring systems into chemical processes.
• Experience with pilot plant operations, including commissioning and execution of test production runs.
• Ability to mentor and review the technical work of junior engineers, providing constructive feedback and guidance.
• Proficiency with Aspen Plus for process modeling and design.
• Experience with modular design and both batch and continuous flow processing.
• Strong problem‑solving skills with the ability to work effectively in a team environment on fast‑paced projects.
• Strong verbal and written communication skills for technical presentations and documentation.
• Sup…