Process Modeling Engineer

This position is listed on behalf of a partner company, who manages all applications and next steps. Our partner is looking for a Process Modeling Engineer based in the United States.

The Process Modeling Engineer will connect advanced process modeling, industrial engineering, and plant operations to optimize next-generation carbon capture and clean energy technologies. In this role, you will develop rigorous techno-economic analyses (TEA) to guide operating decisions for demonstration and commercial-scale production facilities. You will refine process models, improve equipment sizing and capital cost estimates, and evaluate performance across different operating conditions and plant configurations.

Working alongside multidisciplinary engineering, research, and operations teams, you will identify opportunities to reduce energy consumption, capital expenditure, and operating costs. You will also help translate complex model outputs into practical design decisions and actionable recommendations. This is an opportunity to contribute to the scale-up of innovative industrial technologies with the potential to reduce atmospheric carbon dioxide.

• Develop and use internal process modeling tools to determine optimal operating conditions for demonstration and production facilities, balancing operating costs, capital expenditure, and energy efficiency.
• Continuously update and improve process models based on design developments, operational data, and advances in materials, including running and optimizing Aspen Custom Modeler (ACM) models.
• Translate Aspen model outputs into Excel-based tools that generate equipment lists, minimum, nominal, and maximum equipment sizing, stream lists, pipe sizing, power requirements, and stream tables.
• Automate model outputs using VBA or similar technologies to generate vendor‑ready equipment specification sheets and perform model consistency checks.
• Collaborate with relevant engineering personnel to transfer process model outputs into Aspen Capital Cost Estimator (ACCE) and related cost estimation tools.
• Compare internal capital cost estimates with estimates from external engineering and design firms to improve accuracy and reliability.
• Use cost estimates and vendor quotations to establish equipment and area‑based costs, sizing assumptions, and scaling exponents for the broader techno‑economic analysis model.
• Develop simplified process models to enable rapid engineering reviews, scenario comparisons, and preliminary technical assessments.
• Work with drafters, designers, and external engineering partners to ensure Process Flow Diagrams (PFDs) and Piping and Instrumentation Diagrams (P&IDs) remain aligned with current process models.
• Integrate design changes and equipment updates into demonstration facility development and construction, using engineering judgment and vendor feedback to optimize equipment selection, reduce costs, and improve process performance.
• Identify opportunities to reduce energy use, capital expenditure (Cap Ex), and operating expenditure (OpEx) through rigorous techno‑economic analysis and fundamental process design optimization.
• Collaborate with materials, site operations, mechanical engineering, R&D, and project management teams to scope experiments and engineering projects, evaluate findings, and incorporate results into updated models.
• Integrate process models and cost data into broader project workflows, identify critical performance variables and data quality gaps, and support life cycle analysis (LCA) and environmental impact assessments.
• Present technical findings, model outputs, cost estimates, and process recommendations clearly to senior leadership, investors, external reviewers, and other stakeholders.