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Sr Process Engineer Jobs in Illinois (NOW HIRING)

Sr Engineer Process

Downers Grove, IL · On-site

$148K - $211K/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 ...

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 ...

$113K - $146K/yr

As a Senior Process Engineer , you will be responsible for designing, optimizing, and standardizing manufacturing processes across plants of varying scale. This role leads cross-functional ...

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 ...

Senior Process Engineer

Vernon Hills, IL · On-site

$103K - $133K/yr

As a Senior Process Engineer, you will play a key role in designing and implementing innovative process solutions for a wide range of projects, from small-scale to large-scale initiatives. You'll ...

Sr. Process Engineer

Oak Brook, IL · On-site

$105K - $135K/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

Aurora, IL · On-site

$95K - $120K/yr

Senior Process Engineer The Role: Our site inAurorais seeking aProcess Development Engineerto join our team! Entegris is a world-leading supplier for the semiconductor industry. We have accomplished ...

Senior Process Engineer

Aurora, IL · On-site

$95K - $120K/yr

Senior Process Engineer The Role: Our site in Aurora is seeking a Process Development Engineer to join our team! Entegris is a world-leading supplier for the semiconductor industry. We have ...

Sr. Process Engineer

Oak Brook, IL · On-site

$105K - $135K/yr

When you join Design Group as a Sr. Process Engineer, you are joining a team that will challenge you and position you for growth. In this role, you will work with a team of industry experts to help ...

Sr. Process Engineer

Oak Brook, IL

$105K - $135K/yr

When you join Design Group as a Sr. Process Engineer, you are joining a team that will challenge you and position you for growth. In this role, you will work with a team of industry experts to help ...

Sr. Process Engineer

Oak Brook, IL · On-site

$105K - $135K/yr

When you join Design Group as a Sr. Process Engineer, you are joining a team that will challenge you and position you for growth. In this role, you will work with a team of industry experts to help ...

Senior Process Engineer

Aurora, IL · On-site

$95K - $120K/yr

Senior Process Engineer The Role: Our site inAurorais seeking aProcess Development Engineerto join our team! Entegris is a world-leading supplier for the semiconductor industry. We have accomplished ...

Senior Process Engineer - Industrial Water

Chicago, IL · On-site

$107K - $138K/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 ...

Senior Process Engineer A Job Location: Vernon Hills, Illinois United States At Tetra Pak we commit to making food safe and available, everywhere; and we protect what's good - protecting food ...

Role Summary The Senior Process Engineering role at Rivian is critical to ensuring we not only meet production milestones but to do so effectively. In this front-line role, you will have a hand in ...

Showing results 21-40

Sr Process Engineer information

See Illinois salary details

$72.7K

$117.4K

$165.2K

How much do sr process engineer jobs pay per year?

As of Aug 10, 2026, the average yearly pay for sr process engineer in Illinois is $117,364.00, according to ZipRecruiter salary data. Most workers in this role earn between $100,800.00 and $130,300.00 per year, depending on experience, location, and employer.

What are the key skills and qualifications needed to thrive as a Sr Process Engineer?

To thrive as a Sr Process Engineer, you need a solid background in chemical, mechanical, or industrial engineering, often with a bachelor's or master's degree and relevant industry experience. Familiarity with process simulation software (such as Aspen Plus or HYSYS), Six Sigma or Lean certifications, and knowledge of safety and regulatory standards are typically required. Strong problem-solving, project management, and communication skills help distinguish top performers in this role. These skills and qualifications are vital for optimizing processes, ensuring efficiency and safety, and driving continuous improvement in complex manufacturing environments.

What is a Sr Process Engineer?

Senior Process Engineers are experienced professionals responsible for designing, optimizing, and overseeing the processes used in manufacturing or production environments. They analyze workflows, troubleshoot process issues, and implement improvements to increase efficiency, reduce costs, and ensure product quality. Sr Process Engineers often lead teams, manage projects, and work closely with other departments such as quality assurance, maintenance, and operations. Their expertise is crucial in industries like chemicals, pharmaceuticals, oil and gas, and food processing. They typically hold a degree in engineering and have several years of experience in process engineering roles.

How does a Sr Process Engineer typically collaborate with cross-functional teams to improve manufacturing efficiency?

Sr Process Engineers work closely with teams such as production, quality assurance, maintenance, and R&D to identify areas for process optimization. They often lead or participate in cross-functional meetings to gather data, analyze workflow bottlenecks, and implement solutions that enhance efficiency and product quality. Effective communication and project management skills are essential, as Sr Process Engineers must balance technical requirements with practical constraints while ensuring all stakeholders are aligned with proposed changes.

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

AspectSr Process EngineerProcess Engineer
QualificationsBachelor's degree in engineering, 5+ years experience, certifications like Six SigmaBachelor's degree in engineering or related field, 1-3 years experience
ResponsibilitiesLead process improvements, optimize manufacturing processes, mentor junior staffAssist in process development, data collection, support process optimization
Work EnvironmentManufacturing plants, industrial facilities, cross-functional teamsManufacturing settings, engineering teams, project-based tasks

The main difference between a Sr Process Engineer and a Process Engineer lies in experience, responsibility level, and scope of work. The Sr Process Engineer typically leads projects, mentors others, and has more advanced qualifications, while the Process Engineer supports and executes process improvements under supervision.

What job categories do people searching Sr Process Engineer jobs in Illinois look for? The top searched job categories for Sr Process Engineer jobs in Illinois are:
What cities in Illinois are hiring for Sr Process Engineer jobs? Cities in Illinois with the most Sr Process Engineer job openings:
Infographic showing various Sr Process Engineer job openings in Illinois as of August 2026, with employment types broken down into 1% As Needed, 80% Full Time, 15% Part Time, 3% Contract, and 1% Nights. Highlights an 92% Physical, 2% Hybrid, and 6% Remote job distribution, with an average salary of $117,364 per year, or $56.4 per hour.

Sr Engineer Process

Zachry Group

Downers Grove, IL • On-site

$148K - $211K/yr

Full-time

Medical, Dental, Vision, Life, Retirement

Re-posted 21 days ago


Zachry Group rating

6.7

Company rating: 6.7 out of 10

Based on 63 frontline employees who took The Breakroom Quiz

63rd of 80 rated construction


Job description


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 process engineering and design tasks for assigned projects
Responsibilities
• 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 work of a small staff of engineers 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.
• Analyze problems and take appropriate action to ensure continuous and reliable operation of equipment and systems.
• Evaluate equipment and processes to ensure compliance with safety and environmental regulations.
• Estimate resource requirements of new project proposals in support of business development.
• Other duties, as assigned.
Qualifications
• Bachelor's Degree in Chemical Engineering
• 15+ years of experience working as a Process Engineer within the Energy & Chemical Industries
• Experience applying standard engineering techniques, procedures, and criteria to ensure compliance with safety and environmental regulations.
• Experience in PFD and P&ID development, and participation in HAZOP/LOPA studies
• Proficient in H&MB development, equipment and instrumentation process specification and performing hydraulic analysis
• Strong knowledge of ASME and API 520/521 with proficiency designing relief devices and associated collection headers
• 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
• Proficient with Process Engineering Software (AspenTech or equivalent)
• Strong desire to learn
PREFERRED QUALIFICATIONS
• Licensed Professional Engineer
• Experience as a Process Engineer in the gas processing and/or refining industries
• Experience in Food and Beverage Industry
• Experience in gas purification technologies such as Pressure Swing Adsorption, Membrane separation, or others
• Knowledge and/or experience in blue and/or green ammonia
• Experience integrating emerging/renewable energy with hydrogen production technologies
• Experience with hydrogen fuel blending in combustion processes
• Experience specifying process equipment in cryogenic services including cold box heat exchangers and pumps
• Experience with designing OSBL/Utility scopes required to support Licensor provided ISBL packages
• 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.
In accordance with Illinois Equal Pay Act, the expected salary range for this Illinois position, Snr. Process Engineer is between $148,000 and $211,490, annually. Actual pay will be adjusted based on experience, geographic location, and other job-related factors as permitted by law.
This position Snr. Process Engineer is eligible for participation in Zachry's Total Employee Rewards Program, which includes medical, dental, vision, life insurance, disability coverage, and other ancillary benefits. This position is also eligible for participation in the 401(k) Retirement Savings Plan.
#LI-JL1 #Process #Engineering

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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