Senior Process Engineer

Position Summary We are seeking a highly experienced, hands-on process engineering leader to drive technical excellence, field execution, and project delivery across modular systems, separations, and revamp projects. This role focuses on process design, plant optimization, and field-based debottlenecking, with a strong emphasis on ethanol, refining, and industrial process systems.

A critical component of this role is on-site field engagement, including real-time data collection and performance analysis to diagnose issues and implement high-impact operational improvements.

Position is remote and will require travel to ethanol plants for field visits with approximately 50% and travel to RCM Thermal Kinetics headquarters in Buffalo NY.

Key Responsibilities Technical Leadership

• Serve as senior technical authority on:

• Distillation & separations

• Heat integration / preheat trains

• Tower internals and mass transfer equipment

• Lead development of:

• Process simulations (Aspen, Pro/II, ChemCAD)

• PFDs / P&IDs / heat & material balances

• Equipment design and datasheets

• Provide expert guidance on revamps, debottlenecking, and grassroots design.

• Ensure engineering solutions are practical, cost-effective, and constructible.

Field Site Assessment & Ethanol Plant Optimization (Core Requirement)

• Lead and personally execute on-site field assessments at ethanol production facilities.

• Collect and validate real-time operating data, including:

• Pressure profiles

• Temperature surveys

• Flow rates and compositions

• Perform unit-level diagnostics across:

• Distillation systems (beer column, rectifier, side strippers)

• Dehydration systems (molecular sieves)

• Evaporation systems (multi-effect evaporators, syrup concentration)

• Conduct plant walkdowns and operator interviews to understand true operating conditions.

• Develop baseline simulation models calibrated with field data.

• Identify and quantify:

• Hydraulic bottlenecks

• Heat transfer limitations

• Control and operability issues

• Generate actionable debottlenecking solutions, including:

• Tower internals upgrades

• Heat integration improvements

• Equipment modifications or revamps

• Translate findings into:

• Process Design Packages (PDPs)

• Revamp scopes and detailed engineering deliverables

• Support implementation and startup to ensure measurable performance improvements.

Project & Execution Oversight

• Lead projects from concept ? design ? execution ? startup

• Ensure alignment between:

• Engineering deliverables

• Fabrication and installation

• Field conditions and constraints

• Serve as technical lead on key projects ($1MM–$10MM+)

• Drive:

• Technical quality

• Schedule adherence

• Scope clarity and risk mitigation

Team Leadership & Capability Building

• Lead and mentor a team of:

• Process engineers

• Design engineers

• Build internal capabilities in:

• Ethanol process systems

• Field data collection and validation

• Simulation-driven debottlenecking

• Train engineers in:

• Field troubleshooting techniques

• Translating plant data into actionable engineering solutions

Product & Engineering Development

• Support development and refinement of:

• Modular distillation systems

• Separation and heat transfer solutions

• Revamp and optimization methodologies

• Standardize engineering approaches and tools for repeatable, high-quality execution.

• Collaborate with fabrication and operations teams to improve design for manufacturability and installation.

Qualifications Required

• B.S. in Engineering (required)

• 15+ years experience in:

• Process engineering (distillation/separations)

• Plant operations support, revamps, or project engineering

• Demonstrated hands-on field experience, including:

• Pressure and temperature surveys

• Real-time data collection and validation

• On-site troubleshooting and test runs

• Deep expertise in:

• Distillation, fractionation, and mass transfer

• Heat exchangers and thermal systems

• Ethanol plant systems (distillation, dehydration, evaporation strongly preferred)

• Proficiency in:

• Process simulation tools (Aspen, PRO/II, ChemCAD)

• Developing heat & material balances and equipment designs

Preferred

• B.S. in Chemical or Process Engineering

• Direct experience with ethanol plant debottlenecking and optimization

• Experience executing revamp projects driven by field data

• Strong understanding of:

• Tower internals and hydraulics

• Heat integration and energy optimization

• Ability to independently perform:

• Site walkdowns

• Data reconciliation and model validation

• Experience with modular system design and implementation

Equal Opportunity Statement RCM is an equal opportunity employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, disability, or status as a protected veteran.

Disclaimer This job description is intended to describe the general nature and the level of the work being performed by the people assigned to this position. It is not intended to include every job duty and responsibility specific to the position. RCM reserves the right to amend and change responsibilities to meet business and organizational needs as necessary.