Chemical Process Engineer Essex Solutions creates innovative magnet wire solutions that power our customers' success. With more than a century of excellence, we are committed to innovation, operational excellence, and a diverse, inclusive workplace. As we continue to grow, we are seeking an experienced Chemical Process Engineer to lead data governance and process monitoring towards current and future automations and to lower variation in the manufacturing processes.
Position Overview:
A Chemical Process Engineer in a polymer resin or enamel facility operates at the intersection of chemistry and mechanical systems. This role is primarily focused on data governance for all stages of resin production while ensuring rigorous safety and quality standards of chemical processing plant of Essex Solutions North America. The incumbent will be responsible for maximizing throughput and yield, precisely controlling polymer rheology, reaction engineering, process tracking, and statistical analysis.
Key Responsibilities: Process Optimization & Monitoring:
- Reaction Engineering: Monitor and optimize polymerization cycles, focusing on temperature and viscosity control, pressure regulation, and raw material addition rates.
- Mass & Energy Balances: Perform detailed calculations to improve raw material efficiency and reduce utility consumption (steam, cooling water/fluid, electricity).Yield Analysis: Identify causes of "off-spec" batches and implement corrective actions to minimize waste.
- Equipment & Infrastructure Optimization:
- System Design: Specify and size equipment such as reactors, heat exchangers, distillation columns, and filtration systems to improve batch sizes and throughput.
- P&ID Development: Maintain and update Piping and Instrumentation Diagrams (P&IDs) and Process Flow Diagrams (PFDs).Automation Support: Collaborate with Controls Engineers to tune PID loops and refine PLC/DCS logic for better process stability.
- Quality & Safety:
- Process Safety Management (PSM): Lead or participate in Hazard and Operability Studies (HAZOP) and Layer of Protection Analysis (LOPA).Quality Integration: Work with the QC lab to ensure resin properties meet specifications, track and analyze QC data.
- RCA (Root Cause Analysis): Utilize Six Sigma or Lean methodologies to investigate process excursions or equipment failures.
- Project Management:
- CAPEX Projects: Support current and future automations. Manage capital expenditure projects from initial scoping and budgeting through commissioning and startup.
- MOC (Management of Change): Oversee the technical documentation and safety reviews required for any process or equipment modifications.
- Culture: Foster accountability, operational discipline, and a continuous improvement mindset.
Qualifications
Education: Bachelor's degree in Chemical/Polymer/Materials Engineering or equivalent.
Experience:
Minimum 2 years experience in a chemical manufacturing environment; resins, coatings, polymers, or plastics preferred.
Strong grasp of polymer rheology, fluid dynamics, and heat transfer. Reaction engineering, process tracking, data logging, yield analysis, and first-line troubleshooting experience highly desired.
Proficiency in process simulation, AutoCAD, and Origin Pro/JMP/similar.
Skills:
Excellent analytical, organizational, and communication skills. Willing to work on-site including navigating around hot surfaces and pressurized vessels. Methodologies: Familiarity with lean principles, problem solving, and continuous improvement tools. Lean or Six Sigma certification preferred.
Work style:- Ability to thrive in a fast-paced changing environment.
- Strong interpersonal skills to effectively collaborate with cross-functional teams.
- Weekend or off-shift work might be necessary occasionally.
- Note on Industry Specifics:
- In a resin plant, "Gel Time" and viscosity build up are critical metrics. A successful Process Engineer must be comfortable managing exothermic reactions where precise cooling-rate control is a matter of both quality and safety.
- Frequent time spent on the plant floor and PPE compliance.
Travel: Willingness to travel up to 20%.
