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Sr Process Engineer Jobs in Virginia (NOW HIRING)

ERG

Senior Process Safety/Chemical Engineer

Fairfax, VA · On-site +1

$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 ...

Merck & Co.

$101K - $131K/yr

  • Medical

  • Dental

  • Vision

  • Retirement

  • PTO

We have an exciting opportunity for a Senior Process Engineer, Technical Operations - Small Molecule Drug Product (Spray Drying) to join our growing team.At our company, we aspire to be the premier ...

Black & Veatch

Sr Wastewater Process Engineer

Virginia Beach, VA · Hybrid

$91K - $118K/yr

  • Medical

  • Dental

  • Vision

  • Life

  • Retirement

  • PTO

Function in a lead wastewater process engineer role as a technical specialist in the areas of conventional wastewater treatment * Use processes such as physical/chemical primary treatment ...

Electra

Senior Materials, Process, & Test Engineer

Manassas, VA · On-site

$130K - $160K/yr

  • Medical

  • Dental

  • Vision

  • Life

  • Retirement

  • PTO

Senior Materials, Process, & Test Engineer About Electra At Electra, we're building the EL9 - a nine-passenger, hybrid-electric aircraft that takes off and lands in 150 feet. Our Ultra Short ...

Phlow Corp.

Process Engineer

Petersburg, VA · On-site

$100K - $150K/yr

  • Medical

  • Life

  • Retirement

  • PTO

Provides mentorship to less senior staff on process design. Implements new solutions for process ... Uses engineering skills to design projects for enhanced safety, quality and or productivity ...

Phlow Corp

Process Engineer

Petersburg, VA

$100K - $150K/yr

  • Medical

  • Life

  • Retirement

  • PTO

Provides mentorship to less senior staff on process design. Implements new solutions for process ... Uses engineering skills to design projects for enhanced safety, quality and or productivity ...

Heico

Process Engineer

Blacksburg, VA · On-site

$65K - $125K/yr

  • Medical

  • Dental

  • Life

  • Retirement

  • PTO

Reporting to the Process Engineering Manager, the Process Engineer will be a key member within our Quality Department. Responsibilities will include: * Support our overseas manufacturing site by ...

HEICO

Process Engineer

Blacksburg, VA · On-site

$65K - $125K/yr

  • Medical

  • Dental

  • Life

  • Retirement

  • PTO

Reporting to the Process Engineering Manager, the Process Engineer will be a key member within our Quality Department. Responsibilities will include: * Support our overseas manufacturing site by ...

HEICO

Process Engineer

Blacksburg, VA · On-site

$65K - $125K/yr

  • Medical

  • Dental

  • Life

  • Retirement

  • PTO

Reporting to the Process Engineering Manager, the Process Engineer will be a key member within our Quality Department. Responsibilities will include: * Support our overseas manufacturing site by ...

Phlow Corp

Process Engineer

Petersburg, VA · On-site

$100K - $150K/yr

  • Medical

  • Life

  • Retirement

  • PTO

Advanced engineering position that leads in process design and execution ... Provides mentorship to less senior staff on process design. Implements new solutions for process ...

Electra

Senior Materials, Process, & Test Engineer

Manassas, VA · On-site

$130K - $160K/yr

  • Medical

  • Dental

  • Vision

  • Life

  • Retirement

  • PTO

The RoleElectra.aero, a next-gen aerospace technology company, seeks a dynamic and driven Senior Materials, Process, & Test Engineer. This role will lead the development, selection, testing, and ...

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Showing results 41-60

All JobsSr Process Engineer JobsSr Process Engineer Jobs in Virginia

Sr Process Engineer information

See Virginia salary details

$74.4K

$120.1K

$169K

How much do sr process engineer jobs pay per year?

As of Aug 15, 2026, the average yearly pay for sr process engineer in Virginia is $120,077.00, 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 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 are popular job titles related to Sr Process Engineer jobs in Virginia?

For Sr Process Engineer jobs in Virginia, the most frequently searched job titles are:

What job categories do people searching Sr Process Engineer jobs in Virginia look for?

The top searched job categories for Sr Process Engineer jobs in Virginia are:

What cities in Virginia are hiring for Sr Process Engineer jobs?

Cities in Virginia with the most Sr Process Engineer job openings:

Sr Process Engineer jobs near you
Infographic showing various Sr Process Engineer job openings in Virginia as of August 2026, with employment types broken down into 1% As Needed, 81% Full Time, 14% Part Time, 3% Contract, and 1% Nights. Highlights an 92% Physical, 2% Hybrid, and 6% Remote job distribution, with an average salary of $120,077 per year, or $57.7 per hour.

Senior Process Safety/Chemical Engineer

ERG

Fairfax, VA • On-site, Remote

$110K - $155K/yr

Full-time

Re-posted 28 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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