Plant Process Engineer

ECOVYST CATALYST TECHNOLOGIES LLC•Hammond, IN

6d•Onsite

About The Position

Ecovyst is a company with over 130 years of history, specializing in sulfur solutions including virgin sulfuric acid, sulfuric acid regeneration services, and sulfuric acid derivatives. They serve diverse industries such as mining (for electronics, EVs, data centers), industrial applications (nylon precursors, lead-acid batteries), water treatment, and refining/petrochemicals. The company operates through Ecoservices (sulfuric acid regeneration, virgin sulfuric acid production, chemical waste handling), Calabrian (sulfur dioxide and derivative solutions), and Chem32 (catalyst activation for refining and renewable fuels). This Plant Process Engineer role is embedded within the production operation, serving as the primary process engineering resource. The position provides day-to-day support to the Production Supervisor and operating team, focusing on troubleshooting, process optimization, and unit performance improvement.

Requirements

B.S. in Chemical Engineering required.
2–5 years of process engineering experience in a chemical manufacturing or process industry environment.
Strong analytical and data interpretation skills, including proficiency with OSIsoft PI Vision and Microsoft Excel for reporting, cost tracking, and process modeling.
Experience with or strong aptitude for production cost analysis, including monitoring and acting on VMC usage data.
Familiarity with PSM and PHMP, including OSHA 1910.119 elements (PHA, MOC, PSSR, mechanical integrity).
Proficiency in SAP for production reporting and Enablon for action item tracking.
Ability to develop, revise, and maintain standard operating procedures.
Ability to read and work from P&IDs, process flow diagrams, and equipment operating manuals.
Strong written and verbal communication skills.
Ability to work in the plant operating area, including climbing stairs, conducting field walks, and wearing appropriate PPE (including SCBA when required).

Nice To Haves

MDC testing and debottlenecking experience preferred.
Demonstrated ability to design and execute production trials, interpret results, and translate findings into operating recommendations.
Working knowledge of DCDA sulfuric acid process or similar gas-phase catalytic chemistry preferred but not required for entry-level candidates.

Responsibilities

Monitor and analyze process data using OSIsoft PI Vision to track key process variables, identify trends, deviations, and issues, and generate performance summaries.
Provide production troubleshooting support to diagnose process upsets, off-spec production, equipment deviations, and unit inefficiencies, developing and communicating corrective operating guidance.
Own Maximum Daily Capacity (MDC) testing and debottlenecking, including designing and executing tests, analyzing results, identifying constraints, and implementing recommendations to maximize throughput.
Oversee Variable Manufacturing Cost (VMC), monitoring cost drivers, comparing actual usage to budget targets, identifying deviations, and implementing changes to reduce operating costs.
Actively participate in Process Hazard Analyses (PHAs) and the site Process Hazard Management Program (PHMP), serving as a technical contributor in reviews and tracking closure of action items.
Support the Management of Change (MOC) process by providing engineering review and technical input on changes affecting production operations.
Own and maintain standard operating procedures (SOPs) for assigned production units, ensuring accuracy and initiating MOCs for revisions.
Support production Key Performance Indicator (KPI) tracking and reporting, including developing and maintaining production dashboards.
Provide process engineering input for turnaround (TA) activities, including scope development, PSSR completion, and monitoring unit performance during startup.
Coordinate with Technical & Capital teams on continuous improvement (CI) initiatives, engineering projects, and process studies.
Support Root Cause Failure Analysis (RCFA) investigations by providing data analysis and engineering expertise.
Actively support and enforce plant HS&E standards and Ecovyst 20 Principles for Managing Behavioral and Operational Safety.
Support Management Team initiatives and drive organizational change.