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Key Responsibilities and Required Skills for Chemical Engineer

💰 $ - $

engineeringchemical-engineeringprocess-engineermanufacturing

🎯 Role Definition

This role requires a results-driven Chemical Engineer responsible for designing, optimizing, and scaling chemical processes and production systems. The ideal candidate blends strong technical process engineering skills (process simulation, mass & energy balances, reactor and separation design), hands-on plant troubleshooting, and process safety leadership (PSM, HAZOP) to drive safe, efficient, and cost-effective manufacturing across pilot and commercial scale. This role partners with R&D, operations, quality, and EHS to deploy robust manufacturing processes, support commissioning and startups, and deliver continuous improvement projects that improve yield, reduce costs, and meet regulatory requirements (GMP, FDA, EPA).

📈 Career Progression

Typical Career Path

Entry Point From:

  • Process Engineer (entry-level) or Chemical Engineering Co-op/Internship
  • Manufacturing Engineer with chemical/process experience
  • R&D Engineer or Pilot Plant Engineer

Advancement To:

  • Senior Chemical Engineer / Lead Process Engineer
  • Process Engineering Manager / Engineering Team Lead
  • Principal Engineer / Technical Fellow

Lateral Moves:

  • Project Engineer (capital projects)
  • Quality / Regulatory Affairs Engineer (GMP/FDA environments)
  • Production/Operations Manager

Core Responsibilities

Primary Functions

  • Lead end-to-end process design and development for chemical production lines, including performing mass and energy balances, sizing equipment (reactors, heat exchangers, distillation columns), and preparing process flow diagrams (PFDs) and P&IDs to translate laboratory methods into safe, scalable manufacturing processes.
  • Conduct process simulation and modeling using tools such as Aspen HYSYS, Aspen Plus, ChemCAD or equivalent to optimize reaction conditions, separation performance, and energy consumption while identifying bottlenecks and mitigating scale-up risks.
  • Manage pilot plant campaigns and scale-up activities from laboratory bench to pilot and full-scale production, designing experiments (DOE), analyzing data, and making recommendations that ensure reproducible, cost-effective manufacturing yields.
  • Drive process safety initiatives including Process Safety Management (PSM) compliance, HAZOP/LOPA facilitation, hazard analyses (HAZID), and the development of safety-critical operating procedures and safeguards to reduce process risk and ensure regulatory compliance.
  • Troubleshoot complex production issues on-site and remotely by performing root cause analysis (RCA), implementing corrective actions, and leading cross-functional problem-solving teams to restore and improve production reliability and quality.
  • Develop and maintain detailed technical documentation: standard operating procedures (SOPs), batch records, equipment specifications, material safety data sheets (MSDS), change control records, and technical reports to support audits and knowledge transfer.
  • Lead continuous improvement projects leveraging Lean, Six Sigma or Kaizen methodologies to improve yield, reduce cycle time, lower operating costs, and minimize waste and environmental footprint across chemical processes.
  • Specify, select, and procure process equipment and control systems, collaborating with vendors and contractors to generate RFQs, evaluate bids, and validate vendor designs against process requirements and safety standards.
  • Support commissioning, start-up and validation activities for new plants and process modifications by developing commissioning plans, performing pre-start reviews, supervising start-up tests, and resolving commissioning issues to achieve guaranteed performance.
  • Collaborate closely with R&D and product development teams to transfer new formulations and chemistries into production, ensuring scale-up feasibility, robustness, and compliance with quality and regulatory standards (GMP, ISO).
  • Implement and optimize process control strategies with instrumentation and control engineers, including PID tuning, advanced control architectures, and integration with DCS/SCADA systems to improve process stability and reduce variability.
  • Lead technical risk assessments and lifecycle reviews for new projects, integrating lessons learned and safety-by-design principals to minimize environmental, health, and safety impacts while meeting project cost and schedule targets.
  • Perform materials selection and corrosion/compatibility assessments for process equipment and piping systems, recommending appropriate alloys, linings, and sealing materials to ensure long-term integrity and regulatory compliance.
  • Develop and execute laboratory and pilot test plans, analyze experimental data using statistical software (Minitab, JMP) and MATLAB/Python, and convert findings into practical process improvements and scale-up guidelines.
  • Manage project budgets and timelines for process improvement and capital projects, coordinating internal resources and external contractors to ensure on-time delivery and cost control while meeting technical performance requirements.
  • Establish and monitor key performance indicators (KPIs) such as yield, throughput, energy intensity, and first-pass quality; prepare periodic reports and present performance updates to operations leadership and stakeholders.
  • Ensure product quality through collaboration with QA/QC, implementing in-process controls, sampling plans, and analytical method validation to meet specifications and support regulatory filings and customer requirements.
  • Execute environmental compliance and waste management strategies, working with EHS to reduce emissions, manage effluents, and comply with EPA/local discharge permits and hazardous waste regulations.
  • Mentor and train junior engineers, technicians, and operators on process fundamentals, troubleshooting techniques, safety procedures, and best practices to build engineering capability and operational excellence.
  • Support cost analyses and techno-economic assessments, identifying opportunities for raw material substitution, energy recovery, and process intensification that improve operating margins and sustainability metrics.
  • Facilitate multidisciplinary project meetings and act as the primary engineering contact between operations, maintenance, procurement, and external licensors to ensure alignment on process objectives and execution details.
  • Conduct life-cycle assessments and sustainability evaluations to recommend process changes that reduce greenhouse gas emissions, improve energy efficiency, and support company sustainability goals.
  • Lead compliance and audit support for internal and external audits (ISO, FDA, local regulators), preparing responses, corrective action plans, and supporting documentation to demonstrate design, operation, and quality control fidelity.
  • Prepare engineering change orders (ECOs), manage process changes through change control systems, and ensure appropriate testing, operator training, and documentation updates prior to implementation.

Secondary Functions

  • Support cross-functional projects by providing technical input for capital planning, procurement specifications, and maintenance strategies.
  • Assist with vendor qualification, factory acceptance testing (FAT), and on-site inspections to verify equipment meets process and safety requirements.
  • Participate in continuous training, safety drills, and incident investigations to strengthen culture of safety and operational discipline.
  • Provide engineering backup for shift operations during abnormal conditions, plant turns, or planned shutdowns to minimize downtime and maintain product quality.
  • Contribute to corporate process engineering standards, design templates, and knowledge base to accelerate future project delivery and standardization.
  • Help prepare regulatory submissions and technical dossiers by supplying process descriptions, validation protocols, and analytical data as needed.

Required Skills & Competencies

Hard Skills (Technical)

  • Strong process design and simulation skills with hands-on experience in Aspen HYSYS, Aspen Plus, ChemCAD, or equivalent process simulation tools for steady-state and dynamic modeling.
  • Expertise in process safety management (PSM), HAZOP/LOPA facilitation, and conducting hazard analyses to identify and mitigate major accident risks.
  • Practical experience with pilot plant operations, scale-up methodologies, design of experiments (DOE), and statistical analysis tools (Minitab, JMP, Python).
  • Solid understanding of reaction engineering, separation processes, heat and mass transfer, and equipment sizing (reactors, distillation columns, heat exchangers, compressors).
  • Competence in developing PFDs, P&IDs, piping specifications, instrumentation lists, and reading/following technical drawings and vendor data sheets.
  • Hands-on familiarity with DCS/SCADA systems and process control strategies, including PID tuning, basic control loops, and integration with PLCs.
  • Experience with material compatibility and corrosion assessments; knowledge of metallurgy and selection of construction materials for chemical environments.
  • Proficiency in technical documentation: SOPs, batch records, commissioning plans, FAT/SAT documentation, and compliance paperwork for audits.
  • Knowledge of quality systems (GMP, ISO), regulatory frameworks (FDA, EPA), and environmental permitting processes relevant to chemical manufacturing.
  • Project management skills including budget management, scheduling, vendor management, and familiarity with capital project execution phases.
  • Solid data analysis skills including mass/energy balance calculations, KPI tracking, and use of Excel, MATLAB, or Python for modeling and reporting.
  • Experience with continuous improvement tools: Lean methods, Six Sigma (Green/Black Belt is a plus), root cause analysis (RCA) and corrective action systems.
  • Familiarity with laboratory analytical techniques (GC, HPLC, titration), quality control testing, and linking lab results to process adjustments.
  • Competence in lifecycle assessment and sustainability metrics related to energy consumption, emissions, and waste reduction strategies.

Soft Skills

  • Strong analytical thinking and structured problem-solving with the ability to synthesize technical data into actionable recommendations.
  • Excellent verbal and written communication skills for clear technical writing, report preparation, and cross-functional stakeholder engagement.
  • Leadership and teamwork capabilities to lead multidisciplinary projects, mentor junior staff, and influence operations and maintenance teams.
  • Detail-oriented with rigorous documentation discipline and a focus on reproducibility, safety, and regulatory compliance.
  • Adaptability and resilience to manage changing priorities, troubleshooting under pressure, and supporting shift operations or plant turnarounds.
  • Project prioritization and time management skills to balance multiple concurrent engineering tasks and deliverables.
  • Customer- and quality-focused mindset, able to translate customer requirements and regulatory constraints into reliable production processes.
  • Proactive continuous improvement orientation with the ability to drive change through data-driven initiatives and stakeholder buy-in.

Education & Experience

Educational Background

Minimum Education:

  • Bachelor of Science (B.S.) in Chemical Engineering or equivalent engineering degree.

Preferred Education:

  • Master of Science (M.S.) or Ph.D. in Chemical Engineering, Process Engineering, or related field for advanced roles or R&D-focused positions.

Relevant Fields of Study:

  • Chemical Engineering
  • Process Engineering
  • Mechanical/Chemical Systems Engineering
  • Materials Science (with chemical processing emphasis)
  • Industrial Engineering (with process manufacturing focus)

Experience Requirements

Typical Experience Range:

  • 2–7 years for intermediate Chemical Engineer roles.
  • 5–12+ years for senior, lead, or specialist positions.

Preferred:

  • 3+ years hands-on manufacturing/process scale-up experience in chemical, petrochemical, specialty chemicals, pharmaceuticals, or related industries.
  • Demonstrated experience leading pilot plant programs, commissioning new equipment, and implementing process safety programs (PSM/HAZOP).
  • Prior exposure to regulated environments (GMP/FDA) or strict environmental compliance programs is highly desirable.
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