CATALYST & POLYMERIZATION STAFF SPECIALIST

Formosa Plastics Group; Point Comfort (TX); On-site; USD 120,000 - 180,000; Full time

Job summary

Formosa Plastics Group in Point Comfort, Texas, is seeking an experienced Catalyst Development Lead to drive innovation in polyolefin catalyst systems. You will oversee lab-scale reactor testing, data analysis, and safety training, interfacing with R&D, operations, and quality teams.

You will lead development and commercialization efforts, build predictive models, and optimize catalyst performance to enhance product quality and cost efficiency in a high-safety environment.

Qualifications

• Minimum of ten (10) years of catalyst reactor testing experience with Ziegler Natta and metallocene technologies.
• Excellent understanding of lab processes, reactor design, process control and catalyst handling.
• Proficient in safety training coordination and laboratory discipline.

Responsibilities

• Lead development, evaluation, optimization, and commercialization of new and improved catalysts.
• Generate, analyze, and interpret catalyst data to establish activity, selectivity, stability, and life.
• Develop predictive models translating lab performance to commercial-unit outcomes.
• Identify opportunities to extend catalyst life, reduce costs, and improve process efficiency.
• Coordinate equipment installation, qualification, and start-up for testing systems.
• Provide technical input during vendor evaluations and procurement.
• Train lab personnel on safe operation of catalyst testing systems.

Skills

Lab-scale reactor operation

Catalyst testing

Data analysis

Process safety

Technical communication

Plant operations understanding

Education

High school diploma or equivalent

Associate’s degree

Bachelor’s degree

Tools

Laboratory equipment procurement

Process safety tools

Job description

I. POSITION OBJECTIVE

Develop new or improved end-use applications for polyolefin resins on various types of converting machines and provide effective assistance to customers and internal business groups to facilitate polyolefin resin sales. To enhance best practices, provide solutions to achieve customer satisfaction. All while sustaining a safe and healthful working environment that meets environmental, health, safety regulations, and company requirements.

II. MAJOR AREAS OF ACCOUNTABILITY

Catalyst Development:

Lead the development, evaluation, optimization, and commercialization of new and improved catalysts to support business growth, cost reduction, product quality, and competitive advantage. Generate, analyze, and interpret catalyst kinetic, physical, chemical, and performance data to establish catalyst activity, selectivity, stability, life, and operating envelopes. Develop predictive models and correlations to translate laboratory and pilot-scale catalyst performance into expected commercial-unit performance. Identify opportunities to improve catalyst performance, extend catalyst life, reduce catalyst consumption, improve process efficiency, and lower overall manufacturing costs. Establish catalyst performance specifications and acceptance criteria in collaboration with R&D, Process Engineering, Operations, Quality, Procurement, and Commercial teams. Help advance catalysts that will afford better value creation and/or cost savings; to help improve the competitiveness of FPC’s product portfolio and product quality to meet customer’s needs.

Laboratory and Testing Support:

Identify, evaluate, specify, and procure catalyst testing equipment, analytical instrumentation, reactors, and supporting laboratory systems to maintain contemporary and leading-edge testing capabilities. Develop equipment specifications, participate in vendor evaluations, and provide technical input during equipment selection and purchasing. Coordinate equipment installation, commissioning, qualification, and start-up to ensure systems meet technical, safety, environmental, and operational requirements. Develop, maintain, and improve laboratory procedures, test methods, operating instructions, and equipment-specific protocols. Ensure catalyst testing equipment is properly maintained, calibrated, and operated within established specifications. Create and administer training programs for new reactors, testing equipment, analytical methods, and laboratory procedures. Train laboratory personnel and other technical staff on safe and effective operation of catalyst testing systems.

Production Trial Support:

Provide direct technical support to production units during production-scale developmental trials of new, modified, or optimized catalysts. Develop detailed production trial plans, including objectives, operating conditions, sampling requirements, performance criteria, safety considerations, and contingency plans. Coordinate laboratory, pilot, and production-scale testing activities to ensure effective scale-up of catalyst technology. Work directly with Operations and Process Engineering to troubleshoot catalyst-related issues during production trials and recommend operating adjustments. Monitor catalyst performance during trials and evaluate activity, selectivity, stability, product quality, throughput, energy efficiency, catalyst consumption, and other relevant commercial metrics. Analyze production trial data and compare results against laboratory and pilot-scale predictions to validate scale-up models and identify opportunities for improvement. Provide real-time technical guidance during trials and make recommendations regarding continuation, modification, or termination of test conditions when appropriate. Lead post-trial evaluations and document results, lessons learned, technical conclusions, and recommendations for future production implementation. Support the transition of successful catalyst technologies from development into routine commercial production.

Process Safety, Quality, and Compliance:

Maintain a strong commitment to process safety and safe laboratory and production practices in all catalyst development activities. Participate in Management of Change (MOC), Process Hazard Analysis (PHA), Pre-Startup Safety Reviews (PSSR), risk assessments, and other applicable process safety activities associated with catalyst development and testing. Ensure catalyst development activities appropriately address hazards associated with chemicals, high temperatures, high pressures, hydrogen, toxic or reactive materials, and laboratory/production reactor systems.

THM:

Promote cleanliness and order through implementation of the Total House Keeping Maintenance program. Emphasize Nothing Touch Ground program and No Visual Pollution program. Maintain the plant like new condition.

III. QUALIFICATIONS

A. TECHNICAL JOB CRITERIA

1. Previous Related Experience Required

A minimum of ten (10) years of catalyst reactor testing experience with both Ziegler Natta and metallocene technologies. Excellent understanding of lab processes, reactor design, process control and catalyst handling.

2. Technical Skills Required to Perform This Job

• Personal computer skills and applicable software.
• Good interpersonal and communication skills.
• Good business writing ability.
• Strong organizational skills.
• Extensive knowledge of B-1 processes.
• Strong background in the installation and operation of various lab scale reactors.
• In-depth knowledge of the air-free handling of catalyst, co-catalysts and raw materials.
• Strong knowledge of the end-use performance of catalysts.
• Strong knowledge of reactor control system programming.
• Good knowledge of product development project structure and compilation of test data.
• Good knowledge of plant contacts and maintenance group processes and capability.
• Direct support of production-scale unit trials using new catalysts.
• To work closely with internal customers and tailor testing needs to their specific applications.
• Working knowledge of the FPC contracting/purchasing and accounting processes.
• Excellent knowledge of workplace safety policies and training coordination.
• Strong troubleshooting and problem-solving skills.
• Mechanical troubleshooting experience.

3. Education

High school diploma or equivalent plus a minimum of 10 years of direct job-related experience required. Associate’s degree with 8 years of direct job-related experience. Bachelor’s degree with 6 years of direct job-related experience preferred.

4. Other Certification/Training Required

• Will require training in Company Policies and Procedures after hire.
• Current employees must meet all technical and safety training requirements for current position, as specified in the Master Training Plan.
• Must participate in the following subject training and pass required certifications.