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Hysys Jobs (NOW HIRING)

Nikkiso Co.

Senior Process Engineer

Irvine, CA · On-site

$111K - $144K/yr

Aspen HYSYS * Validate simulation models against: * Design basis * Vendor data * Operating conditions * Perform sensitivity studies and optimization analyses * Generate simulation-based deliverables ...

CANUSA EPC LLC

Process Engineer Lead - Oil & Gas

Denver, CO · On-site

$106K - $138K/yr

Build and review process simulation models using BRE ProMax, AspenTech HYSYS, or similar software. * Perform and review equipment, piping, valve, and PSV sizing calculations. * Support relief system ...

Kids for the Future

Process Engineer

Houston, TX · On-site

Perform process simulations using Aspen HYSYS, Aspen Plus, ProMax, or equivalent software to support design, debottlenecking, and optimization studies. * Conduct hydraulic calculations and line ...

Nikkiso

Senior Process Engineer

Irvine, CA · On-site

$111K - $144K/yr

Aspen HYSYS * Validate simulation models against: * Design basis * Vendor data * Operating conditions * Perform sensitivity studies and optimization analyses * Generate simulation-based deliverables ...

Polaris Engineering

Senior Process Engineer

Lake Charles, LA · On-site

$95K - $123K/yr

Extensive Process Simulation experience (HYSYS, UNISYS preferred) * P. E. license preferred * Available for short-term travel IV. REPORTING REQUIREMENTS: Reports to the Process Department Engineer ...

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How much do hysys jobs pay per hour?

As of Sep 14, 2026, the average hourly pay for hysys in the United States is $25.47, according to ZipRecruiter salary data. Most workers in this role earn between $17.55 and $29.57 per hour, depending on experience, location, and employer.

What is a HYSYS?

A Hysys job typically involves using Aspen Hysys, a process simulation software, to model and optimize chemical processes in industries such as oil and gas, refining, and petrochemicals. Professionals in this role analyze process performance, design equipment, and troubleshoot operational issues. They may work as process engineers, simulation specialists, or consultants to improve efficiency and safety in industrial operations. Strong knowledge of thermodynamics, process design, and simulation techniques is essential for success in this field.

What does a HYSYS do?

Professionals in a HYSYS-focused position generally spend their days developing and optimizing process simulations using Aspen HYSYS software, analyzing plant data, and working closely with process engineers to troubleshoot operational challenges. They may also participate in project meetings, prepare technical reports, and present simulation results to both engineering and management teams. Collaboration is frequent, as HYSYS specialists often consult cross-functional groups, including operations, safety, and instrumentation teams, to ensure simulation outputs align with real-world requirements. Continuous learning is important, as new software updates and evolving industry standards require ongoing professional development.

What are the key skills and qualifications needed to thrive in the HYSYS position?

To thrive in a HYSYS role, you need a solid background in chemical engineering principles and process modeling, typically supported by a degree in chemical engineering or a related field. Proficiency with Aspen HYSYS process simulation software is essential, and additional certifications in process simulation may be advantageous. Strong analytical thinking, attention to detail, and effective communication skills set top performers apart. These skills and qualifications are crucial for accurately modeling chemical processes, troubleshooting design issues, and collaborating with multidisciplinary teams to ensure optimal plant performance.

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Hysys jobs near you
Infographic showing various Hysys job openings in the United States as of September 2026, with employment types broken down into 3% Internship, 93% Full Time, 1% Part Time, and 3% Contract. Highlights an 84% Physical, 9% Hybrid, and 7% Remote job distribution, with an average salary of $52,986 per year, or $25.5 per hour.

Staff Process Modeling Engineer

Houston, TX • On-site

Mariana Minerals
See more jobs at Mariana Mineralsexternal

$100K - $160K/yr

Full-time

Re-posted 19 days ago

Job description

About Mariana Minerals
Mariana Minerals is a software-first, vertically integrated minerals company on a mission to supply the critical minerals powering modern energy, AI, and defense technologies. We're reimagining the minerals supply chain by combining deep industry expertise with advanced software, automation, and data-driven decision-making.
The Role
Mariana Minerals is seeking a highly motivated Staff Process Modeling Engineer to support the development of next-generation refining processes for critical minerals - key to enabling the world's energy transition.
In this role, you will be responsible for developing, validating, and optimizing heat and material balance models using tools such as ASPEN Plus/HYSYS, SysCAD, OLI Studio, or METSIM. You will work closely with R&D, pilot operations, and project execution teams to translate lab and pilot data into robust, scalable process models that drive the design of first-of-a-kind mineral refining facilities.
As a Staff Process Modeling Engineer, you will serve as a technical leader for process simulation and modeling, providing subject matter expertise across multiple projects, developing modeling standards and best practices, and mentoring junior engineers while partnering with cross-functional teams to support process development from concept through commercial deployment.
What You'll Do
  • Develop steady-state and dynamic process models to establish heat and material balances for integrated mineral refinery systems using ASPEN, SysCAD, OLI, or METSIM.
  • Automate equipment and process sizing (reactors, heat exchangers, filters, crystallizers, evaporators, and separators) based on model outputs, linking models to datasheets and other engineering tools
  • Develop and maintain process simulation databases, ensuring consistency and traceability between modeling assumptions, test data, and engineering deliverables.
  • Calibrate and reconcile models using pilot or plant operating data to ensure model fidelity and predictive accuracy.
  • Conduct process optimization studies - evaluating energy/heat recovery, recycle strategies, and material efficiency improvements.
  • Develop dynamic process models to validate PLC and DCS programming and evaluate/optimize buffer sizing throughout the design.
  • Link process models to CAPEX and OPEX estimation tools, automating technoeconomic model development
  • Document modeling methodologies and results, providing clear technical communication for design reviews, techno-economic assessments, and regulatory submissions.
What You'll Bring
  • Bachelor's degree or higher in Chemical Engineering, Mechanical Engineering, Process Engineering, Metallurgical Engineering, or a closely related engineering discipline
  • 8+ years of experience developing and applying process simulation models for chemical processing, hydrometallurgy, mining, refining, or related industrial process systems.
  • Proficiency in one or more of the following process simulation tools:
    • ASPEN Plus / HYSYS
    • SysCAD
    • OLI Studio / OLI Flowsheet
    • METSIM
  • Deep understanding of mass transfer, heat transfer, thermodynamics, fluid flow, and reaction engineering.
  • Experience developing material and energy balances for multi-step, integrated process systems.
  • Strong grasp of chemical equilibria and phase behavior in aqueous and non-aqueous systems.
  • Familiarity with data reconciliation, parameter fitting, and model validation using experimental or operational data.
  • Competency with Python or MATLAB for model automation, data processing, and custom calculations is a strong plus.
  • Experience integrating process modeling outputs into EPC deliverables (PFDs, P&IDs, equipment datasheets, control narratives, etc.)
Our culture is built on four principles:
Everyone Gets Home Safe. We never put speed or cost ahead of people.
Extreme Ownership. We take full responsibility for outcomes, relentlessly driving toward solutions.
Engineer Out Requirements, then Automate. We simplify, optimize, and then automate for scale.
Share Your Legos. We collaborate openly, share knowledge, and empower each other to build bigger, better solutions.
Join us as we build the future of responsible mineral sourcing and supply!

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