Senior Process Development Engineer Jobs in Richmond, VA

Position Summary: The Senior Process Engineer interacts with the plant teams, business groups and R&D to identify and drive improvements that will optimize and sustain plant operations and help grow the business.  This position ensures that process safety, environmental, and engineering standards are met at all times during normal operation and the implementation of any process changes. 

Duties and Responsibilities:

• Become an expert on the process chemistry, the operating philosophy, and the process design basis for the equipment in plant operating areas supported by the role
• Provide technical support to plant operating areas to help meet site goals through troubleshooting and continuous improvement
• Work within cross-functional teams to track performance as well as develop and implement productivity projects with the overall goal of achieving improved safety, reduced product variability, more efficient use of energy, higher yields, better production rates, and higher attainment
• Development and ownership of daily tracking systems to monitor performance of various process and plant KPIs (Key Process Indicators).
• Lead and support the development of Process Design Packages for capital improvements.  Support capital engineering with Project Punch-listing, Commissioning and Startup
• Manage engineering design deliverables for small and large projects including:
  • Process design narratives, including key technologies and risk summaries
  • Integration of design principles for operability, maintainability and reliability
  • Process simulations
  • Heat and Material Balances Process Flow Diagrams, and Piping and Instrumentation Diagrams
  • Process equipment and instrumentation sizing and specification
  • Evaluation of Process Economics
  • Control system narratives
• Effective use of OSHA-PSM elements including Process Hazards Analysis, Management of Change, Pre-Startup Safety Review, and Standard Operating Procedures
• Identify and implement improvements on basic control schemes and advanced process control strategies
• Develop process economics, feasibility studies, and project justification pitches
• Ensure quality assurance of engineering calculations, process simulations, and engineering drawings

Basic Qualifications:

• B.S. or greater degree in chemical or mechanical engineering
• 4+ years process, production, and/or manufacturing engineering experience as a degreed engineer in industries such as: chemical, petroleum, polymer, pulp & paper or pharmaceutical
• Strong commitment to process and occupational safety, and environmental compliance

Additional Qualifications:

• 7+ years process, production, and/or manufacturing engineering experience as a degreed engineer in industries such as: chemical, petroleum, polymer, pulp & paper, or pharmaceutical. Polymer/resin processing experience preferred
• Six Sigma certification and/or experience in using quality and statistical tools to drive operational improvements including control charts, process capability, and measurement system analysis
• Strong written and verbal communication skills
• Capable of managing multiple priorities and projects
• Demonstrated ability to work effectively at all levels of an organization and in cross-functional teams including salaried and hourly co-workers
• Strong computer skills, specifically Excel, ASPEN, PipeFlo, Minitab, PowerBI, SAP
• Familiarity with chemical plant Distributed Control Systems (DCS), Foxboro, Experion and/or advanced process control a plus
• Demonstrated ability to generate significant process improvements in areas of process safety, environmental systems, yield, energy and capacity
• Incident investigation and root cause analysis
• Experience in the fundamentals of production troubleshooting, optimization, and design for a broad range of unit operations including reaction, hydrogenation, distillation, continuous centrifugation, filtration, heat exchange, solids handling, slurry and liquid material transfer, and utility systems
• Experience with Front-End-Loading (FEL) and stage gate project development for major capital projects
• Experience in OSHA-PSM application – hazard analyses, MOC/PSSR, SOPs, etc
• Must be self-motivated and goal-oriented with proven success working independently and in a multi-functional team environment
• Excellent organizational, planning, and verbal and written communication skills
• Able to manage multiple projects
• Able to use influence to accomplish goals and objectives

The base pay range for this role is $95,000 to 142,600 annually.