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Process Modeling Engineer Jobs (NOW HIRING)

Mariana Minerals

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 ...

MonoSol

Senior Scientist Process Modeling

Chicago, IL · On-site

$94K - $128K/yr

This role sits at the intersection of engineering fundamentals, computational modeling, and real-world manufacturing impact. As a senior individual contributor, you'll lead the development of process ...

MonoSol

Senior Scientist Process Modeling

Chicago, IL · On-site

$94K - $128K/yr

We're looking for an experienced process scientist or engineer with a strong foundation in first-principles modeling and chemical engineering to accelerate how we scale products and evaluate process ...

MonoSol

$67K - $92K/yr

This role sits at the intersection of engineering fundamentals, computational modeling, and real-world manufacturing impact. As a senior individual contributor, you'll lead the development of process ...

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Process Modeling Engineer information

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$92K

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How much do process modeling engineer jobs pay per year?

As of Sep 13, 2026, the average yearly pay for process modeling engineer in the United States is $92,018.00, according to ZipRecruiter salary data. Most workers in this role earn between $74,500.00 and $103,000.00 per year, depending on experience, location, and employer.

What does a process modeling engineer do?

A Process Modeling Engineer is responsible for designing, analyzing, and optimizing processes within industries such as manufacturing, chemical production, or energy. They use mathematical models and simulation software to predict how processes will perform under various conditions. By creating digital models, they help improve efficiency, reduce costs, and ensure safety and quality standards are met. Their work often involves collaborating with other engineers and stakeholders to implement improvements based on data-driven insights.

What are the key skills and qualifications needed to thrive as a process modeling engineer?

To thrive as a Process Modeling Engineer, you need a strong background in chemical or process engineering, analytical problem-solving skills, and typically a relevant engineering degree. Familiarity with process simulation software such as Aspen Plus, HYSYS, or MATLAB, and understanding of industry standards are crucial for effective modeling and analysis. Strong communication, teamwork, and project management skills help you collaborate with cross-functional teams and convey complex technical information. These skills ensure accurate process optimization, efficient project execution, and drive operational improvements in manufacturing or industrial environments.

What are some typical challenges faced by process modeling engineers when collaborating with cross-functional teams?

Process Modeling Engineers often work closely with teams from operations, R&D, and IT to develop and refine models that optimize manufacturing or chemical processes. A common challenge is translating complex technical data into actionable insights that are easily understood by non-engineering stakeholders. Effective communication and adaptability are key, as project requirements can evolve rapidly and may require balancing competing priorities. Building strong relationships and maintaining open channels for feedback help ensure that process models align with both technical standards and business goals.

What is the difference between Process Modeling Engineer vs Process Improvement Specialist?

AspectProcess Modeling EngineerProcess Improvement Specialist
Required CredentialsBachelor's in Engineering, Industrial Engineering, or related field; proficiency in process modeling softwareBachelor's in Engineering, Business, or related field; certifications like Six Sigma often preferred
Work EnvironmentEngineering teams, manufacturing plants, or R&D labsOperational teams, manufacturing facilities, or corporate offices
Employer & Industry UsageManufacturing, aerospace, automotive, and industrial sectorsManufacturing, healthcare, logistics, and service industries

The Process Modeling Engineer focuses on creating detailed process models using specialized software to optimize workflows. In contrast, the Process Improvement Specialist concentrates on analyzing existing processes and implementing improvements, often utilizing methodologies like Six Sigma. Both roles require similar educational backgrounds but differ in their primary focus and tools used.

What cities are hiring for Process Modeling Engineer jobs?

Cities with the most Process Modeling Engineer job openings:

What states have the most Process Modeling Engineer jobs?

States with the most job openings for Process Modeling Engineer jobs include:

What are popular job titles related to Process Modeling Engineer jobs?

For Process Modeling Engineer jobs, the most frequently searched job titles are:

Process Modeling Engineer jobs near you
Infographic showing various Process Modeling Engineer job openings in the United States as of August 2026, with employment types broken down into 1% As Needed, 79% Full Time, 16% Part Time, 3% Contract, and 1% Nights. Highlights an 90% Physical, 2% Hybrid, and 8% Remote job distribution, with an average salary of $92,018 per year, or $44.2 per hour.

Staff Process Modeling Engineer

Houston, TX • On-site

Mariana Minerals
See more jobs at Mariana Mineralsexternal

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Re-posted 13 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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