Senior Process Engineer – Hydrogen, Refining & Petrochemical Systems
Required Skills
Job Description
**Job Overview**
* We are seeking a highly motivated and experienced Senior Process Engineer to lead process design, analysis, and optimization efforts for advanced hydrogen and industrial gas systems serving refinery and petrochemical applications.
* This role is critical to the development, scale\-up, and deployment of process technologies involving hydrogen recovery, purification, compression, PSA systems, and related balance\-of\-plant equipment.
* The ideal candidate brings deep experience in refinery and petrochemical process environments, with a strong understanding of hydrogen systems, gas handling, separation processes, and process integration.
* This individual will play a key role in process modeling, system design, pilot and commercial deployment, troubleshooting, and cross\-functional execution.
* Experience with Ansys modeling tools is highly valued, particularly for fluid, thermal, structural, and multiphysics analysis.
Key Responsibilities
* Lead process engineering activities for hydrogen, gas separation, purification, compression, and related process systems for industrial applications.
* Develop process designs, PFDs, P\&IDs, heat and material balances, process narratives, equipment specifications, and operating philosophies for pilot and commercial systems.
* Support the design and optimization of pressure swing adsorption (PSA) units, hydrogen recovery systems, gas cleanup systems, and integration into refinery and petrochemical plant environments.
* Perform process simulations and engineering analyses to evaluate system performance, bottlenecks, operability, and reliability under varying operating conditions.
* Use Ansys tools for process and equipment modeling, including fluid flow, heat transfer, structural interaction, and multiphysics analysis, as needed to support design and optimization.
* Work closely with mechanical, electrical, controls, and manufacturing teams to ensure process requirements are translated into robust and scalable system designs.
* Lead process hazard reviews, troubleshooting, root cause analysis, and risk assessments to improve performance, safety, and operability.
* Support pilot deployments and commercial projects, including site integration, commissioning, startup planning, test execution, and performance validation.
* Interface with customers, partners, EPCs, and plant personnel to gather site data, define design basis, and support implementation in refinery and petrochemical facilities.
* Drive continuous improvement in process efficiency, hydrogen recovery, system reliability, and cost reduction.
* Contribute to technical reports, design reviews, proposals, and supporting documentation for internal and external stakeholders.
* Ensure compliance with relevant engineering codes, safety standards, and industry best practices applicable to refinery, petrochemical, and hydrogen systems.
Qualifications
* Bachelor’s degree in Chemical Engineering, Mechanical Engineering, Process Engineering, or a related field. Advanced degree is a plus.
* Significant experience in process engineering within refineries, petrochemical plants, industrial gas, hydrogen, or related energy and process industries.
* Strong experience with hydrogen systems, including hydrogen purification, compression, recovery, separation, and gas process integration.
* Hands\-on knowledge of PSA systems and related gas separation technologies is strongly preferred.
* Experience developing process deliverables such as PFDs, P\&IDs, mass and energy balances, equipment datasheets, control narratives, and operating procedures.
* Proficiency in engineering and modeling tools, with direct experience in Ansys for fluid, thermal, or multiphysics modeling highly desirable.
* Strong understanding of plant utilities, gas handling systems, piping and instrumentation, and process control in industrial settings.
* Experience supporting pilot plants, demonstration units, or first\-of\-a\-kind process systems from design through commissioning is a plus.
* Familiarity with process safety methodologies such as HAZOP, What\-If reviews, LOPA, and management of change processes.
* Ability to troubleshoot complex process issues, perform root cause analysis, and implement practical engineering solutions.
* Strong communication and collaboration skills, with the ability to work effectively across technical disciplines and with external industrial stakeholders.
Preferred Background
* Experience with refinery off\-gas, syngas, hydrogen networks, SMR/PSA systems, or petrochemical gas streams.
* Experience in scaling technologies from pilot to commercial deployment.
* Familiarity with industrial codes and standards applicable to pressure equipment, piping, hazardous areas, and process plants.
* Experience in startup, commissioning, and field support for industrial process systems.
Why Join Us
* This is an opportunity to help build and deploy next\-generation hydrogen and process technologies for some of the most impo
* We are seeking a highly motivated and experienced Senior Process Engineer to lead process design, analysis, and optimization efforts for advanced hydrogen and industrial gas systems serving refinery and petrochemical applications.
* This role is critical to the development, scale\-up, and deployment of process technologies involving hydrogen recovery, purification, compression, PSA systems, and related balance\-of\-plant equipment.
* The ideal candidate brings deep experience in refinery and petrochemical process environments, with a strong understanding of hydrogen systems, gas handling, separation processes, and process integration.
* This individual will play a key role in process modeling, system design, pilot and commercial deployment, troubleshooting, and cross\-functional execution.
* Experience with Ansys modeling tools is highly valued, particularly for fluid, thermal, structural, and multiphysics analysis.
Key Responsibilities
* Lead process engineering activities for hydrogen, gas separation, purification, compression, and related process systems for industrial applications.
* Develop process designs, PFDs, P\&IDs, heat and material balances, process narratives, equipment specifications, and operating philosophies for pilot and commercial systems.
* Support the design and optimization of pressure swing adsorption (PSA) units, hydrogen recovery systems, gas cleanup systems, and integration into refinery and petrochemical plant environments.
* Perform process simulations and engineering analyses to evaluate system performance, bottlenecks, operability, and reliability under varying operating conditions.
* Use Ansys tools for process and equipment modeling, including fluid flow, heat transfer, structural interaction, and multiphysics analysis, as needed to support design and optimization.
* Work closely with mechanical, electrical, controls, and manufacturing teams to ensure process requirements are translated into robust and scalable system designs.
* Lead process hazard reviews, troubleshooting, root cause analysis, and risk assessments to improve performance, safety, and operability.
* Support pilot deployments and commercial projects, including site integration, commissioning, startup planning, test execution, and performance validation.
* Interface with customers, partners, EPCs, and plant personnel to gather site data, define design basis, and support implementation in refinery and petrochemical facilities.
* Drive continuous improvement in process efficiency, hydrogen recovery, system reliability, and cost reduction.
* Contribute to technical reports, design reviews, proposals, and supporting documentation for internal and external stakeholders.
* Ensure compliance with relevant engineering codes, safety standards, and industry best practices applicable to refinery, petrochemical, and hydrogen systems.
Qualifications
* Bachelor’s degree in Chemical Engineering, Mechanical Engineering, Process Engineering, or a related field. Advanced degree is a plus.
* Significant experience in process engineering within refineries, petrochemical plants, industrial gas, hydrogen, or related energy and process industries.
* Strong experience with hydrogen systems, including hydrogen purification, compression, recovery, separation, and gas process integration.
* Hands\-on knowledge of PSA systems and related gas separation technologies is strongly preferred.
* Experience developing process deliverables such as PFDs, P\&IDs, mass and energy balances, equipment datasheets, control narratives, and operating procedures.
* Proficiency in engineering and modeling tools, with direct experience in Ansys for fluid, thermal, or multiphysics modeling highly desirable.
* Strong understanding of plant utilities, gas handling systems, piping and instrumentation, and process control in industrial settings.
* Experience supporting pilot plants, demonstration units, or first\-of\-a\-kind process systems from design through commissioning is a plus.
* Familiarity with process safety methodologies such as HAZOP, What\-If reviews, LOPA, and management of change processes.
* Ability to troubleshoot complex process issues, perform root cause analysis, and implement practical engineering solutions.
* Strong communication and collaboration skills, with the ability to work effectively across technical disciplines and with external industrial stakeholders.
Preferred Background
* Experience with refinery off\-gas, syngas, hydrogen networks, SMR/PSA systems, or petrochemical gas streams.
* Experience in scaling technologies from pilot to commercial deployment.
* Familiarity with industrial codes and standards applicable to pressure equipment, piping, hazardous areas, and process plants.
* Experience in startup, commissioning, and field support for industrial process systems.
Why Join Us
* This is an opportunity to help build and deploy next\-generation hydrogen and process technologies for some of the most impo
Posted: 2026-03-09