Senior Process Engineer

Cheshire Solutions Limited; United Kingdom; On-site; GBP 100,000 - 125,000; Full time

Job summary

A leading engineering firm is seeking a Senior Process Engineer specializing in high-temperature and solids handling processes. The successful candidate will optimize production performance and lead process improvements in a 24/7 manufacturing environment. Ideal candidates will have over 5 years of industry experience and a Bachelor's degree in a relevant engineering field. The role includes excellent benefits and opportunities for career progression.

Benefits

Competitive base salary

Performance-based bonus

Comprehensive benefits package

Professional development opportunities

Career progression

Qualifications

• 5+ years of experience in high-temperature processing industries.
• Proven manufacturing or operations leadership experience.
• Strong understanding of thermochemical and solids flow processes.

Responsibilities

• Lead and optimize high-temperature process units.
• Drive improvements in process stability and product quality.
• Analyze process data to identify and rectify issues.

Skills

Process optimization

Data analysis

Manufacturing leadership

Communication skills

Problem-solving

Team leadership

Education

Bachelor's degree in Chemical Engineering, Process Engineering, or Mechanical Engineering

Tools

Aspen

HYSYS

MATLAB

Excel VBA

DCS/PLC

Job description

Job Title: Senior Process Engineer - High Temperature / Solids Processing Operations

Location: Houston

Reports to: Operations Manager / Plant Manager

Department: Manufacturing / Operations / Process Engineering

Position Summary:

We are seeking an experienced Process Engineer with a strong background in high-temperature, solids-handling processes such as calcination, gasification, coking, rotary kiln, cement, or drying operations. The ideal candidate will be responsible for optimizing production performance, leading process improvements, and supporting safe, reliable, and efficient operation of large-scale thermal process units. This role requires a hands‑on engineer with manufacturing and operations leadership experience, capable of bridging the gap between technical process performance and day‑to‑day plant operations.

Key Responsibilities:

• Lead and optimize the operation of high-temperature process units (e.g., calciners, gasifiers, kilns, cokers, dryers).
• Drive improvements in process stability, product quality, throughput, and energy efficiency.
• Work closely with operations teams to ensure safe, compliant, and reliable plant performance.
• Analyze process data to identify root causes of variability or downtime, implementing corrective actions.
• Lead or support continuous improvement and debottlenecking projects within the plant.
• Develop and maintain standard operating procedures (SOPs) and process documentation.
• Collaborate with maintenance and reliability teams to address equipment performance issues and plan outages.
• Support commissioning and start‑up activities for new or modified process equipment.
• Train and mentor plant operators and junior engineers in process fundamentals and best practices.
• Ensure environmental, health, and safety standards are upheld in all process activities.

Qualifications and Experience:

• Bachelor's degree (or higher) in Chemical Engineering, Process Engineering, Mechanical Engineering, or a related field.
• 5+ years of experience in high-temperature or solids-processing industries such as cement, gasification, coking, calcination, rotary kiln, or industrial drying.
• Proven track record of manufacturing or operations leadership, ideally within a 24/7 continuous production environment.
• Strong understanding of thermochemical and solids flow processes, heat and mass transfer, and reaction kinetics.
• Experience with process modeling, simulation, and data analysis tools (e.g., Aspen, HYSYS, PI, MATLAB, Excel VBA).
• Familiarity with process control systems (DCS/PLC) and instrumentation in high-temperature units.
• Demonstrated ability to lead cross-functional teams and drive operational improvements.
• Excellent communication, problem-solving, and decision-making skills.

Preferred Skills:

• Experience with refractory systems, combustion optimization, and gas‑solid interaction.
• Knowledge of environmental compliance (emissions, off‑gas treatment, waste heat recovery).
• Six Sigma / Lean Manufacturing certification or equivalent experience.
• Experience with project engineering, CAPEX implementation, and vendor management.
• Familiarity with safety management systems (e.g., PSM, HAZOP, MOC processes).

Compensation and Benefits:

• Competitive base salary (commensurate with experience).
• Performance-based bonus.
• Comprehensive benefits package (health, pension, insurance).
• Professional development and training opportunities.
• Career progression within manufacturing and operations leadership.