Job Purpose
The Process Engineer is responsible for designing, optimizing, and troubleshooting production processes in refineries, petrochemical plants, or energy facilities to ensure safe, efficient, and cost-effective operations. The role involves process simulation, debottlenecking, and compliance with environmental and safety regulations. Key Responsibilities
1. Process Design & Optimization

• Develop and improve process flow diagrams (PFDs), piping and instrumentation diagrams (P&IDs), and heat/material balances.
• Conduct process simulations using Aspen HYSYS, CHEMCAD, or Petro-SIM to optimize yields, energy efficiency, and emissions.
• Identify and implement debottlenecking solutions to increase plant capacity.

2. Production Support & Troubleshooting

• Monitor plant performance using DCS/SCADA systems and analyze key performance indicators (KPIs).
• Investigate process deviations, quality issues, and equipment failures using root cause analysis (RCA).
• Recommend corrective actions to minimize downtime and improve reliability.

3. Safety & Environmental Compliance

• Ensure adherence to SABS, OSHA, and ISO 14001 standards.
• Conduct HAZOP (Hazard and Operability Studies), LOPA (Layer of Protection Analysis), and SIL (Safety Integrity Level) assessments.
• Implement carbon footprint reduction strategies (e.g., flare gas recovery, waste heat utilization).

4. Project Management

• Lead process-related capital projects (e.g., catalyst upgrades, column revamps).
• Collaborate with mechanical, instrumentation, and operations teams for plant modifications.

5. Energy Efficiency & Sustainability

• Optimize heat exchanger networks (Pinch Analysis) and steam systems.
• Support green hydrogen, biofuels, or carbon capture (CCUS) initiatives.

Required Qualifications

• Bachelor’s Degree in Chemical/Process Engineering (BEng/BSc).
• Professional Registration with ECSA (advantageous).
• Additional Certifications:
  • Process Safety Management (PSM) certification.
  • Six Sigma Green/Black Belt (for process optimization).
  • Project Management (PMP/PRINCE2).

Essential Skills & Competencies
Technical Skills

• Process Simulation: Aspen HYSYS, CHEMCAD, PRO/II.
• Instrumentation & Control: Understanding of DCS, PLCs, and process alarms.
• Thermodynamics & Reaction Engineering: Knowledge of distillation, catalysis, and reactor design.
• Data Analysis: Advanced Excel, Python, or MATLAB for trend analysis.

Soft Skills

• Strong problem-solving for troubleshooting complex processes.
• Communication skills for cross-departmental coordination.
• Analytical mindset for interpreting process data.

Experience Requirements

• 3–5 years in refining, petrochemicals, or energy (Sasol, PetroSA, Engen, Eskom).
• Experience with cracking, reforming, polymerization, or gas-to-liquid (GTL) processes.
• Familiarity with SAP PM or Maximo for maintenance workflows.