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About the job

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

Salary Range:

$80,000 - $125,000

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.

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