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Process Simulation Optimization Engineer Jobs (NOW HIRING)

Mariana Minerals

Staff Process Modeling Engineer

Houston, TX · On-site

$100K - $160K/yr

In this role, you will be responsible for developing, validating, and optimizing heat and material ... As a Staff Process Modeling Engineer, you will serve as a technical leader for process simulation ...

Mariana Minerals

$150 - $200/hr

In this role, you will be responsible for developing, validating, and optimizing heat and material ... As a Staff Process Modeling Engineer, you will serve as a technical leader for process simulation ...

New

Optimized Process Designs

Senior Process Engineer

Katy, TX · On-site

$150 - $200/hr

Optimized Process Designs, LLC (OPD), a Koch company, is seeking Senior Process Engineer to join ... The ideal candidate will have hands‑on experience with process simulation software, a strong ...

ITG Brands

Process Optimization Engineer

Greensboro, NC · On-site

$103K - $138K/yr

Own standardized equipment and the change management system for the assigned process. * Serve as engineering's primary point of contact for technology and platform-related topics. * Provide ...

Nikkiso Co.

$100 - $125/hr

Job Overview The Senior Process Engineer leads process system design and technical definition for ... Perform sensitivity studies and optimization analyses * Generate simulation-based deliverables ...

Nikkiso

Senior Process Engineer

Irvine, CA · On-site

$100 - $125/hr

Job Overview The Senior Process Engineer leads process system design and technical definition for ... Perform sensitivity studies and optimization analyses * Generate simulation-based deliverables ...

Trafigura Group

$125 - $150/hr

This role is well suited to a process/project engineer with early-career power and/or oil asset ... Key Responsibilities Splitter Asset Optimization (approx. 50%) Run and maintain LP-based ...

Puma Energy

Optimization Engineer

Houston, TX · On-site

$100 - $125/hr

This role is well suited to a process/project engineer with early-career power and/or oil asset ... Key Responsibilities Splitter Asset Optimization (approx. 50%) Run and maintain LP-based ...

Trafigura

Optimization Engineer

Houston, TX · Hybrid

This role is well suited to a process/project engineer with early-career power and/or oil asset ... Key Responsibilities Splitter Asset Optimization (approx. 50%) * Run and maintain LP-based ...

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Process Simulation Optimization Engineer information

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$190.5K

How much do process simulation optimization engineer jobs pay per year?

As of Sep 9, 2026, the average yearly pay for process simulation optimization engineer in the United States is $123,399.00, according to ZipRecruiter salary data. Most workers in this role earn between $92,000.00 and $146,500.00 per year, depending on experience, location, and employer.

What does a process simulation optimization engineer do?

A Process Simulation Optimization Engineer is responsible for designing, modeling, and improving industrial processes using advanced simulation software. They analyze complex systems, identify inefficiencies, and use mathematical models to optimize process performance, reduce costs, and improve product quality. Their work is crucial in industries such as manufacturing, chemical engineering, and energy, where process efficiency directly impacts profitability and sustainability. These engineers collaborate with cross-functional teams to implement data-driven solutions and ensure optimal operation of processes.

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

To thrive as a Process Simulation Optimization Engineer, you need a solid background in chemical or process engineering, advanced mathematics, and experience with process modeling, typically supported by a relevant engineering degree. Expertise in simulation software such as Aspen Plus, HYSYS, or MATLAB, and knowledge of optimization algorithms are highly valued, along with certifications like Six Sigma or related credentials. Strong analytical thinking, problem-solving, and effective communication skills help engineers translate complex data into actionable improvements and work collaboratively with cross-functional teams. These competencies are crucial for optimizing industrial processes, reducing costs, and ensuring safety and efficiency in engineering operations.

How does a process simulation optimization engineer typically collaborate with cross-functional teams during a project?

Process Simulation Optimization Engineers work closely with process engineers, operations staff, and data analysts to develop and refine models that optimize plant performance. Regular collaboration includes sharing simulation results, gathering input on operational constraints, and jointly evaluating proposed process improvements. Effective communication and teamwork are essential, as the engineer often translates complex simulation data into actionable recommendations for various stakeholders, ensuring that optimization aligns with safety, quality, and production goals.

What is the difference between Process Simulation Optimization Engineer vs Process Engineer?

AspectProcess Simulation Optimization EngineerProcess Engineer
CredentialsBachelor's or Master's in Chemical, Mechanical, or Industrial Engineering; familiarity with simulation softwareBachelor's or Master's in Chemical, Mechanical, or Industrial Engineering; often includes process design experience
Work EnvironmentDesign labs, simulation software, project teamsPlant floors, design offices, operational settings
Industry UsageManufacturing, chemical, oil & gas, energy sectorsManufacturing, chemical, oil & gas, energy sectors

The Process Simulation Optimization Engineer focuses on developing and optimizing process models using simulation tools to improve efficiency and performance. In contrast, the Process Engineer is more involved in designing, implementing, and maintaining manufacturing processes on-site. Both roles require similar educational backgrounds and industry experience, but their daily tasks and work environments differ significantly.

What are popular job titles related to Process Simulation Optimization Engineer jobs?

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

Infographic showing various Process Simulation Optimization Engineer job openings in the United States as of September 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 $123,399 per year, or $59.3 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 14 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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