Senior Process Engineer

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The Senior Process Chemical Engineer is responsible for leading the design, development, scale-up, construction support, commissioning, and optimization of chemical manufacturing processes and facilities from laboratory concept through pilot plant and full-scale commercial production.

This role requires deep expertise in chemical process design, equipment design, process calculations, pilot plant development, experimentation, statistical process control, and data-driven process improvement. The engineer will serve as a senior technical leader within the Global Process Engineering Group, supporting global manufacturing operations, capital projects, new product introduction, process safety, regulatory compliance, and continuous improvement initiatives

• Lead the design, development, scale-up, and implementation of chemical manufacturing processes from laboratory scale to pilot plant and commercial production.
• Develop and review process engineering deliverables, including process flow diagrams, P&IDs, mass balances, energy balances, heat transfer calculations, fluid flow calculations, equipment sizing, utility demand calculations, process control narratives, and operating envelopes.
• Provide technical leadership for the design and construction of chemical manufacturing facilities, including greenfield and brownfield projects, process skids, reaction systems, mixing systems, filtration systems, transfer systems, storage tanks, utility systems, and supporting infrastructure.
• Apply engineering standards and regulatory expectations, including API, ASME, OSHA, EPA, NFPA, and other applicable codes, to support safe and compliant process and equipment design.
• Support pressure relief, venting, containment, flammable vapor, hazardous material handling, and process safety evaluations in collaboration with EH&S and external engineering resources.
• Lead or support equipment design and specifications, including reactors, vessels, tanks, pumps, heat exchangers, condensers, filters, piping systems, instrumentation, control valves, relief devices, and utility equipment.
• Develop technical specifications, scopes of work, bid packages, equipment datasheets, vendor requirements, and engineering documentation for capital projects.
• Review vendor drawings, equipment submittals, fabrication packages, installation drawings, and construction documentation to ensure alignment with process requirements and applicable standards.
• Support capital project execution, including design reviews, vendor selection, contractor coordination, factory acceptance testing, site acceptance testing, installation, commissioning, and startup.
• Design, execute, and analyze pilot plant trials to evaluate process feasibility, scale-up risks, operating windows, material compatibility, quality impacts, and manufacturing robustness.
• Develop experimental plans using sound engineering and statistical methods, including design of experiments, hypothesis testing, sampling plans, capability studies, and process validation approaches.
• Apply statistical process control, data analytics, and process performance monitoring to identify variation, improve yield, reduce defects, and increase manufacturing consistency.
• Analyze manufacturing data using tools such as Excel, Minitab, JMP, Python, SQL, Tableau, or equivalent platforms to support data-driven decision-making.
• Troubleshoot complex process, equipment, quality, and scale-up issues using structured root cause analysis, engineering calculations, statistical analysis, and plant data.
• Drive continuous improvement in throughput, cycle time, yield, quality, safety, cost, reliability, and process capability.
• Collaborate with R&D, Operations, Quality, EH&S, Maintenance, Automation, Supply Chain, and external vendors to ensure successful technology transfer and manufacturability of new and existing products.
• Support process automation and control strategies, including instrumentation selection, control philosophy, PLC/DCS interface requirements, data historian needs, and process monitoring requirements.
• Lead process risk assessments, design reviews, process hazard…