Process Engineer

Role & responsibilities

Key Responsibilities:

1. Process Design & Optimization

• Develop and optimize process flow diagrams (PFDs), piping and instrumentation diagrams (P&IDs), and material and energy balances (MEBs).
  
• Perform heat and mass balance calculations for unit operations (e.g., distillation, heat exchange, reaction kinetics).
  
• Conduct hydraulic calculations for pipeline and pump sizing using Bernoullis equation and Darcy-Weisbach formula.
  
• Simulate processes using tools such as Aspen Plus, HYSYS, CHEMCAD, or MATLAB.
  
• Calculate equipment specifications (heat exchangers, reactors, vessels, compressors, etc.) based on process requirements.
  

2. Data Analysis & Troubleshooting

• Analyze operational data (flow rates, temperatures, pressures, compositions) to identify inefficiencies, deviations, or bottlenecks.
  
• Use root cause analysis (RCA) and Failure Modes and Effects Analysis (FMEA) to address process failures.
  
• Perform statistical analysis and process capability studies (Cp, Cpk, Six Sigma tools) for process control and quality improvements.
  

3. Continuous Improvement & Project Work

• Lead process improvement projects using Lean Six Sigma methodologies.
  
• Perform cycle time, yield, and throughput calculations to assess improvements.
  
• Collaborate with cross-functional teams (QA, production, maintenance, EHS) to implement process changes.
  
• Support commissioning, qualification, and validation (IQ, OQ, PQ) of new processes and equipment.
  

4. Compliance & Documentation

• Prepare detailed technical documentation including engineering calculations, operating procedures, control strategies, and risk assessments (HAZOP, LOPA).
  
• Ensure compliance with relevant safety, quality, and environmental standards (e.g., OSHA, ISO 9001, GMP, API).
  
• Contribute to audits, safety reviews, and incident investigations.