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Senior Process Engineer Jobs in Washington, DC (NOW HIRING)

ERG

Senior Process Safety/Chemical Engineer

Fairfax, VA · On-site

$110K - $155K/yr

ERG is seeking a Senior Process Safety Engineer or Chemical Engineer to join our Risk Management Program (RMP) and Process Safety Management (PSM) compliance and enforcement team providing support to ...

Black & Veatch

Sr. PFAS Process Engineer

Arlington, VA · On-site

$119K - $154K/yr

The Black & Veatch Process Engineers develop technical solutions that are critical to winning work and drive design deliverables for critical infrastructure projects with community benefits. Our Team ...

Black & Veatch

Sr. PFAS Process Engineer

Arlington, VA · On-site

$119K - $155K/yr

Why BVs Process Engineering Team? * The work is rewarding and meaningful * The team is comprised of supportive and appreciative professionals * Career opportunities exist in many rapidly expanding ...

Black & Veatch

Sr. PFAS Process Engineer

Arlington, VA · On-site

$119K - $155K/yr

The Black & Veatch Process Engineers develop technical solutions that are critical to winning work and drive design deliverables for critical infrastructure projects with community benefits. Our Team ...

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All JobsProcess Engineer JobsSenior Process Engineer JobsSenior Process Engineer Jobs in Washington, DC

Senior Process Engineer information

See Washington, DC salary details

$84.9K

$137.1K

$193K

How much do senior process engineer jobs pay per year?

As of Sep 3, 2026, the average yearly pay for senior process engineer in Washington, DC is $137,125.00, according to ZipRecruiter salary data. Most workers in this role earn between $117,700.00 and $152,300.00 per year, depending on experience, location, and employer.

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

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 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.

How much does a senior process engineer earn?

A senior process engineer typically earns between $80,000 and $130,000 annually, depending on experience, industry, and location. They often have specialized skills in process optimization, project management, and may hold certifications like Six Sigma or PE licensure.

What are the most commonly searched types of Process Engineer jobs in Washington, DC?

The most popular types of Process Engineer jobs in Washington, DC are:

What are popular job titles related to Senior Process Engineer jobs in Washington, DC?

For Senior Process Engineer jobs in Washington, DC, the most frequently searched job titles are:

What job categories do people searching Senior Process Engineer jobs in Washington, DC look for?

The top searched job categories for Senior Process Engineer jobs in Washington, DC are:

Senior Process Engineer jobs near you
Infographic showing various Senior Process Engineer job openings in Washington, DC as of August 2026, with employment types broken down into 1% As Needed, 71% Full Time, 25% Part Time, 2% Contract, and 1% Nights. Highlights an 86% Physical, 2% Hybrid, and 12% Remote job distribution, with an average salary of $137,176 per year, or $66 per hour.

Senior Process Safety/Chemical Engineer

ERG

Fairfax, VA • On-site

$110K - $155K/yr

Full-time

Re-posted 17 days ago

Job description

ERG is a research and consulting firm that provides a wide range of support to federal, state, and commercial clients. ERG offers multidisciplinary teams with nationally recognized skills in engineering, science, economics, public health, informational technology, and communications. We hire people with the best minds and then provide them with a vibrant and flexible environment in which to develop their careers. The qualified individual must be highly motivated with the skills to prioritize, perform, and communicate effectively in a fast-paced environment.
ERG is seeking a Senior Process Safety Engineer or Chemical Engineer to join our Risk Management Program (RMP) and Process Safety Management (PSM) compliance and enforcement team providing support to our local, State, and Federal clients. The ideal candidate will be responsible for leading technical engineering and compliance investigations in relation to Section 112(r) of the Clean Air Act (both the General Duty Clause and RMP), as well as applicable Emergency Preparedness and Community Right-to-Know Act (EPCRA) and Comprehensive Environmental Response, Compensation, and Liability Act (CERCLA) requirements. The Senior Process Safety Engineer or Chemical Engineer would help to expand our growing team in this area both in areas of expertise and client base.
Job Description:
  • Direct medium to large scale complex projects to ensure internal and external expectations are met for scope, budget, schedule and quality
  • Review and interpret technical engineering documentation, including but not limited to: offsite consequence analyses (OCAs), process safety information; process hazard analyses (PHAs); operating procedures; training records; mechanical integrity programmatic records; management of change (MOC) and pre-startup safety review (PSSR) packages; compliance audits; incident investigations; employee participation plans; hot work permits; contractor management plans; and emergency response programs and procedures
  • Lead and support on-site compliance evaluations and inspections
  • Engage comfortable with personnel at facilities in the following industry types: petroleum refineries, chemicals manufacturing facilities, anhydrous ammonia refrigeration facilities, flammable storage facilities, natural gas processing plants, and chemical storage warehouses
  • Manage and train junior and mid-level staff to facilitate growth
  • Collaborate and communicate effectively with multiple clients and internal stakeholders regarding project progress and budget status
  • Occasional travel to investigation sites (up to 25%)

Qualifications and Skills:
  • 10-15 years of experience in process safety and/or chemical engineering
  • EPA RMP, OSHA PSM, and/or similar state-level program compliance experience
  • Proven project manager with ability to manage multiple projects and subcontractors on time and on budget
  • Ability to prioritize, perform, and communicate effectively in a fast-paced environment
  • Be able to carry 25 pounds, climb ladders, and work on elevated platforms

$110,000 - $155,000 a year
ERG is an equal opportunity employer and complies with all applicable EEOC regulations. All qualified applicants will receive consideration for employment without regard to age, race, color, religion, sex, sexual preference, national origin, disability, or status as a protected veteran.
Please be aware, the only authentic corporate domain for ERG is https://www.erg.com. ERG may, on occasion, screen applicants via telephone or video interviews via Skype, Teams, GoToMeeting, or another type of video platform. However, any candidate extended a job offer might be asked to meet in person with an ERG employee before providing confidential personal information associated with new employment.
If you're a qualified individual with a disability or a disabled veteran, you have the right to request a reasonable accommodation if you are unable or limited in your ability to use or access ERG's online application process as a result of your disability. To request accommodation, please contact Human Resources via email at [email protected] or call (781) 674-7293.
ERG fosters a friendly, flexible work environment. ERGers are dedicated to serving clients who are committed to making the world a better place. We promote and recognize principles of fairness and respect in the work we do, the partnerships we foster, and the culture we value both within and outside of our organization.

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