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Senior Process Engineer Jobs in Aurora, IL (NOW HIRING)

Sr Engineer Process

Downers Grove, IL · On-site

$103.80K - $134.20K/yr

Zachry Group is currently accepting applications for a Senior Process Engineer with Power Experience for our Downers Grove Engineering Design Center. Successful candidate will be responsible for ...

Sr Engineer Process

Downers Grove, IL · On-site

$103.80K - $134.20K/yr

Zachry Group is currently accepting applications for a Senior Process Engineer in our Downers Grove Engineering Design Center . Successful candidate will be responsible for leading a team supporting ...

Sr. Process Engineer

Oak Brook, IL

$105K - $135.70K/yr

... Sr. Process Engineer The Process Engineer analyzes process data to identify inefficiencies in the sterilization process and implements appropriate improvements. The Engineer also leads development ...

Senior Process Engineer - Industrial Water

Chicago, IL · On-site

$107.20K - $138.60K/yr

The role of the Senior Process Engineer is to productively network with a wide array of engineering, environmental, water and wastewater professionals on both technical project execution and related ...

Sr Process Safety Engineer Chicago, Illinois, United States About the Job Sr Process Safety Engineer No sponsorship provided. Candidates must be US Citizen or Green Card Holder. The Sr Process Safety ...

Sr. Process Technician

Lockport, IL · On-site

$90K - $153.20K/yr

The Senior Process Technician serves as a subject matter expert for blow-molding processes ... Collaborate with Production, Maintenance, and Engineering to eliminate recurring defects, equipment ...

The Senior Process Technician serves as a subject matter expert for blow-molding processes ... Collaborate with Production, Maintenance, and Engineering to eliminate recurring defects, equipment ...

The Senior Process Technician serves as a subject matter expert for blow-molding processes ... Collaborate with Production, Maintenance, and Engineering to eliminate recurring defects, equipment ...

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Showing results 1-20

Senior Process Engineer information

See Aurora, IL salary details

$74.4K

$120.1K

$169K

How much do senior process engineer jobs pay per year?

As of May 28, 2026, the average yearly pay for senior process engineer in Aurora, IL is $120,078.00, according to ZipRecruiter salary data. Most workers in this role earn between $103,100.00 and $133,300.00 per year, depending on experience, location, and employer.

What are the key skills and qualifications needed to thrive as a Senior Process Engineer, and why are they important?

To thrive as a Senior Process Engineer, you need a strong background in chemical or process engineering, problem-solving skills, and typically a bachelor's or master's degree in a relevant field. Expertise in process simulation software (such as Aspen Plus or HYSYS), Six Sigma or Lean certifications, and familiarity with process control systems are highly valued. Outstanding analytical abilities, leadership, and effective communication set top performers apart in this role. These skills and qualifications are crucial for optimizing processes, ensuring safety and compliance, and leading teams to achieve operational excellence.

What are some common challenges Senior Process Engineers face when working on cross-functional teams?

Senior Process Engineers often collaborate with professionals from various departments, such as operations, quality, and maintenance. A common challenge is aligning diverse priorities and communication styles to achieve shared project goals. Successfully managing these differences requires strong interpersonal and project management skills, as well as the ability to translate technical concepts for non-engineering colleagues. Regular meetings and clear documentation can help ensure everyone stays informed and engaged throughout the process.

What does a Senior Process Engineer do?

A Senior Process Engineer is responsible for designing, optimizing, and overseeing processes within manufacturing or production environments. They analyze workflows, troubleshoot issues, and implement improvements to increase efficiency, safety, and product quality. Senior Process Engineers often lead projects, mentor junior engineers, and collaborate with cross-functional teams to ensure operational excellence. Their expertise is vital in industries like chemicals, pharmaceuticals, oil and gas, and food processing.

What is the difference between Senior Process Engineer vs Process Engineer?

AspectSenior Process EngineerProcess Engineer
QualificationsBachelor's or Master's in Engineering, often with 5+ years experienceBachelor's degree in Engineering or related field, typically 1-3 years experience
ResponsibilitiesLeading process improvements, mentoring, project managementSupporting process development, data analysis, assisting senior staff
Work EnvironmentDesign teams, manufacturing plants, R&D departmentsManufacturing facilities, engineering teams, operational support

Senior Process Engineers typically have more experience, leadership duties, and oversee complex projects, while Process Engineers focus on supporting process development and implementation. Both roles are essential in manufacturing and engineering industries, but the senior role involves greater responsibility and strategic planning.

What are the most commonly searched types of Process Engineer jobs in Aurora, IL? The most popular types of Process Engineer jobs in Aurora, IL are:
What are popular job titles related to Senior Process Engineer jobs in Aurora, IL? For Senior Process Engineer jobs in Aurora, IL, the most frequently searched job titles are:
What cities near Aurora, IL are hiring for Senior Process Engineer jobs? Cities near Aurora, IL with the most Senior Process Engineer job openings:
Sr Engineer Process

Sr Engineer Process

Zachry Group

Downers Grove, IL • On-site

$103.80K - $134.20K/yr

Full-time

Posted 7 days ago


Zachry Group rating

6.7

Company rating: 6.7 out of 10

Based on 58 frontline employees who took The Breakroom Quiz

58th of 77 rated construction


Job description

Zachry Group is currently accepting applications for a Senior Process Engineer with Power Experience for our Downers Grove Engineering Design Center.  Successful candidate will be responsible for leading a team supporting process engineering and design tasks for assigned projects.

    Bachelor's Degree in Chemical or Mechanical Engineering, or related engineering discipline 
    15+ years of experience working as a Process Engineer within the Power and/or Energy & Chemical Industries
    Proficient in H&MB development, equipment and instrumentation process specification and performing hydraulic analysis
    Strong knowledge of ASME and API standards
    Proficient with Process Engineering Software (AspenTech or Thermoflow suite preferred)
    Good Communication Skills (Active Listening, Verbal, and Written)
    Ability to adapt to changing client requirements while defining a new path and remaining a positive role model for the team
    Excellent Attention to Detail - in own work as well as demonstrated in checking work of others
    Proven history of meeting schedule commitments and planning resources required
    Judgment and Decision Making
    Strong desire to learn

PREFERRED QUALIFICATIONS
    Licensed Professional Engineer
    Experience in the EPC Power business
    Experience in Nuclear Industry
    Experience Utilizing the Thermoflow suite of Software Tools to develop HMB and TIC estimates 
    Experience with designing BOP/OSBL/Utility scopes required for full project execution
    Knowledge of Performance Guarantees including emissions compliance
    Past exposure to environmental permitting and citing studies

PHYSICAL DEMANDS
Employee will be required to communicate in person, via telephone, email, use of arm/hand steadiness, manual dexterity, finger dexterity, multi limb coordination, oral expression, and comprehension. May be required to lift, carry, and move objects safely.

WORK ENVIRONMENT
Will work in a general office environment. Capable of operating and functioning in a fast-paced work environment. Must possess a vision (corrected or uncorrected) that allows for clear visibility from a distance of 20 inches or less.

The above description covers the fundamental responsibilities of the Senior Process Engineer position. It shall not be construed as a complete listing of all miscellaneous, incidental, or similar duties which may be required from day-to-day.

Zachry Group is dedicated in providing a Safe and Drug Free work environment; and is an Equal Opportunity Employer.
 

    Responsible for serving as Process Lead on an EPC power Project, or equivalent.  Should have experience in system design engineering in the power industry.
    Responsible for developing process flow diagrams (PFD) and piping & instrumentation diagrams (P&ID).
    Responsible for sizing and rating various equipment like pumps, horizontal and vertical vessels, heat exchangers, and air coolers.
    Responsible for performing hydraulic analysis and calculations for piping systems.  Experience to include evaluating systems involving single phase, two phase, slurries, water hammer, slug flow, and distribution networks.  Tools required should range from spreadsheet through rigorous software evaluations.
    Capable of supervising, coordinating, and reviewing the work of engineers on the team to accomplish project objectives.
    Mentors younger engineers, leading by example.  Supports department development initiatives and standards creation/review/update.
    Participate in various client Process Hazard Analysis reviews (i.e. risk review, HAZID, HAZOP/LOPA).
    Responsible for design of relief system, flare header design, relief valve sizing and performing contingency analysis and flare header analysis.
    Evaluates, selects, and applies standard engineering techniques, procedures, and criteria, using judgment in making adaptations and modifications.
    Present technical information to peers (internal or external) for review and comment.
    Evaluate equipment and processes to ensure compliance with safety and environmental regulations.
    Estimate resource requirements of new project proposals in support of business development.
    As a Licensed Professional Engineer, seals and signs all documentation produced by own work. May also seal and sign work done by engineers under direct supervision.
    Other duties, as assigned.
 


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About Zachry Group

Sourced by ZipRecruiter

Zachry Group is America's pacesetter in turnkey construction, engineering, maintenance, turnaround and fabrication services in the power, energy, chemicals, manufacturing and industrial sectors. It works with customers to plan, build, and renew their most critical facilities, so they can achieve their immediate and long-term goals, all at the highest safety standards. Zachry Group operates 35 offices, and averages 20,000 employees working in more than 400 locations nationwide. Please visit www.zachrygroup.com for more information.

Industry

Construction

Company size

10,000+ Employees

Headquarters location

San Antonio, TX, US

Year founded

1924