Senior Process Engineer Jobs in Munster, IN (NOW HIRING)

Backed by an over 130-year history, Ecovyst has evolved into a platform of leading sulfur solutions united by a shared commitment to reliability, innovation, and performance. We have carefully cultivated our reputation as a premier provider of virgin sulfuric acid, sulfuric acid regeneration services, and sulfuric acid derivatives. We provide specialty grade high-purity virgin sulfuric acid for a number of diverse and growing end uses. Among them are mining, particularly copper for electronics applications, production of electric vehicles and the ongoing expansion of data centers across the globe, and industrial applications including our customers’ production of nylon precursors, production of lead acid batteries for all types of vehicles, industrial and municipal water treatment, and refining and petrochemical processes.

• Ecoservices provides sulfuric acid regeneration, produces virgin sulfuric acid, and offers chemical waste handling and treatment services
• Calabrian produces high-value sulfur dioxide and derivative solutions, enabling us to serve a broader set of essential industries
• Chem32 sulfides and activates catalysts for refining and renewable fuel processes

What we offer:

• Competitive pay
• Full benefit package
• 401k matching
• Tuition Reimbursement

Only local candidates to Hammond, IN will be considered

Position Overview:

Serve as the primary process engineering resource embedded within the production operation provide day-to-day process engineering support to the Production Supervisor and operating team for troubleshooting, process optimization, and unit performance improvement.

What you will be doing:

• Monitor and analyze process data using OSIsoft PI Vision — track key process variables (temperatures, pressures, flows, concentrations, conversion efficiency) across all production units; identify trends, deviations, and developing issues; generate process performance summaries and reports for the Production Supervisor and Operations Manager.
• Provide production troubleshooting support — assist the Production Supervisor and operators in diagnosing process upsets, off-spec production, equipment deviations, and unit inefficiencies; develop and communicate corrective operating guidance; participate in post-event reviews and document learnings.
• Own MDC (Maximum Daily Capacity) testing and debottlenecking — design and execute MDC tests in coordination with the Production Supervisor; analyze test results; identify process and operational constraints that limit throughput; develop and implement operating recommendations to maximize production to MDC rate; document results and track improvement actions.
• Own VMC (Variable Manufacturing Cost) oversight — monitor and track variable manufacturing cost drivers per ton of acid produced including water, electricity, Mag Hydroxide, and sulfur/spent acid feed ratios; compare actual usage to budget targets; identify deviations and opportunities to reduce operating costs; develop and implement operating changes to improve VMC efficiency; report VMC performance to Operations Manager on a regular cadence.
• Participate actively in PHAs and the site PHMP (Process Hazard Management Program) — serve as an active technical contributor in all PHA and HAZOP reviews per the PHMP revalidation schedule; ensure current operating conditions, known deviations, and production constraints are accurately represented in hazard scenarios; track and drive closure of PHA action items assigned to the operations function in Enablon; support accurate maintenance of PHMP documentation.
• Support the MOC (Management of Change) process for operational and process changes — provide process engineering review and technical input on MOCs affecting production operations; assist with documentation and training coordination.
• Own and maintain standard operating procedures (SOPs) for assigned production units — ensure procedures accurately reflect current operating conditions, approved operating limits, and best practices; initiate MOCs for any required procedure revisions.
• Support production KPI tracking and reporting — assist in developing and maintaining production dashboards covering OEE, MDC rate, VMC, and SUMO status; generate process performance summaries for daily and weekly production reviews.
• Support turnaround (TA) activities — provide process engineering input on TA scope development; participate in PSSR completion; monitor unit performance during startup and ramp-up to MDC; identify and respond to post-TA process deviations.
• Coordinate with the Technical & Capital teams on CI initiatives, engineering projects, and process studies assigned by the Operations Manager.
• Support RCFA investigations — provide process data analysis and engineering expertise; participate in incident investigation teams; develop corrective action recommendations.
• Actively support and enforce the plant’s HS&E standards and Ecovyst 20 Principles for Managing Behavioral and Operational Safety.
• Support Management Team initiatives and help drive organizational change.

Required Qualifications:

• B.S. in Chemical Engineering required; 2–5 years of process engineering experience in a chemical manufacturing or process industry environment.
• Strong analytical and data interpretation skills — ability to use OSIsoft PI Vision for process data trending, deviation identification, and performance analysis; Microsoft Excel for reporting, cost tracking, and process modeling.
• Experience with or strong aptitude for production cost analysis — ability to monitor, interpret, and act on VMC usage data (water, electricity, raw material consumption rates) to drive operating cost reduction.
• MDC testing and debottlenecking experience preferred; demonstrated ability to design and execute production trials, interpret results, and translate findings into operating recommendations.
• PSM and PHMP familiarity required — working knowledge of OSHA 1910.119 elements including PHA, MOC, PSSR, and mechanical integrity; must be capable of serving as an active technical contributor in PHA and HAZOP reviews; familiarity with the PHMP revalidation schedule, action item tracking, and documentation requirements.
• Proficient in SAP for production reporting, notification entry, and work order support; Enablon for action item tracking; Microsoft Excel and PowerPoint.
• Ability to develop, revise, and maintain standard operating procedures — must be able to interpret current operations and translate them into clear, accurate written procedures.
• Ability to read and work from P&IDs, process flow diagrams, and equipment operating manuals.
• Strong written and verbal communication skills — able to communicate process engineering findings and recommendations clearly to operators, supervisors, and site leadership.
• Ability to work in the plant operating area — climb stairs, conduct field walks, and work wearing appropriate PPE including SCBA when required.
• Working knowledge of DCDA sulfuric acid process or similar gas-phase catalytic chemistry preferred but not required for entry-level candidates.