Engineer, Sr. Process Design

PBF Energy; Oregon (OH); Hybrid; USD 120,000 - 180,000; Full time

Job summary

PBF Energy seeks a Sr. Process Design Engineer to lead multidisciplinary process design projects across the refinery, guiding concepts from inception to funding and commissioning.

You will own the relief valve and flare programs, perform sizing calculations, and maintain related databases, while supporting safety, environmental, and operational improvements. The role requires strong communication, leadership, and collaboration with process engineering leads and capital projects teams to meet

Qualifications

• B.S. in Chemical Engineering required.
• 5+ years of relevant petrochemical experience required, with some process design experience preferred.
• Project development experience in a refinery or chemical plant environment is required.
• Experience in using HYSYS or other process design software required.
• PSPPM or other PSV sizing software experience preferred.
• Demonstrated ability to lead multidisciplinary reviews and mentor junior engineers.
• Excellent verbal and written communication skills.
• Capable of interfacing with multiple departments to drive and steward common goals.
• Must be self-motivated, results oriented and schedule driven.

Responsibilities

• Project Development: Support the Project Team with project engineering requirements, including process design input, technical reviews, scope definition, and alignment with engineering standards and best practices.
• Relief Valve and Flare system: Own and SME for site’s relief valve and flare systems; perform sizing, calculations, and maintenance of related databases and mitigation plans.
• Process Design, Engineering & Optimization: Size equipment, evaluate processes for performance and energy efficiency, support FEED and detailed engineering, develop PFDs and P&IDs.
• Standards Compliance & Process Safety Review: Ensure designs meet safety, environmental, and regulatory requirements; support safety/environmental impact assessments.
• Execution Support & Field Coordination: Support commissioning and startup activities including procedures and post-audit.
• Collaboration, Mentoring & Knowledge Sharing: Mentor engineers and collaborate with operations, maintenance, reliability, safety, and environmental teams.
• Digital Tools & Communication: Use PI System, Seeq, HYSYS for troubleshooting and optimization; prepare technical reports and presentations.

Skills

Leadership

Verbal and written communication

Cross-functional collaboration

Interfacing with multiple departments

Education

B.S. in Chemical Engineering

Tools

HYSYS

PSPPM

Job description

Engineer, Sr. Process Design

The Process Design Engineer provides process engineering design and project support for multidisciplinary projects across all units within the refinery; managing project concepts from inception to capital funding approval and through commissioning. As a member of the Process Engineering team, the Process Design Engineer supports the Capital Projects group in developing and guiding process and project design. Additionally, this role will own the sites relief valve and flare system programs, including the sizing, validation and mitigation plans. Other duties may include supporting unit troubleshooting, identifying and implementing process improvements, supporting site safety and environmental groups, and may assume additional process engineering responsibilities as needed.

RESPONSIBILITIES

1. Project Development: Support the Project Team with project engineering requirements, including process design input, technical reviews, scope definition, and alignment with engineering standards and best practices. Identify and evaluate capital and optimization projects aligned with safety, environmental, and economic goals and standards. Collaborate with business team, technical, and project teams resources to advance initiatives. Issue Requests for Proposals to outside companies in support of completing process engineering studies. Evaluate proposals and manage studies conducted by outside engineering firms.
2. Relief Valve and Flare system: Act as owner and SME for site’s relief valve and flare systems. Preforming all required calculations to support day-to-day operation as well as project development. Maintain the refinery PSV database, relief scenarios, calculations, documentation, and inspection/maintenance requirements. Perform relief valve sizing, relief system calculations, and maintain the PSPPM database. Develop and implement mitigation plans for PSV maintenance and inspection.
3. Process Design, Engineering & Optimization: Perform equipment sizing and specification (pumps, heat exchangers, columns, reactors, piping, etc.). Evaluate existing processes for performance improvements, yield enhancement, energy efficiency, and operating cost reductions. Support Front-End Engineering Design (FEED) and detailed engineering phases. Develop and optimize process flow diagrams (PFDs), piping and instrumentation diagrams (P&IDs), and heat and material balances.
4. Standards Compliance & Process Safety Review: project designs addressing process design, safety, environmental compliance, reliability, operability, constructability, and cost estimation. Ensure project development complies with PBF’s capital project best practices, industry design standards, and site-specific requirements. Demonstrate knowledge of all safety, health and environmental issues that impact the refinery and personnel to ensure the project design considers safety and environmental potential impacts. Adhere to all applicable legislation, regulations, codes, and standards. Take action to address safety/environmental concerns and mitigate risks. Share results of safety/environmental impact assessments with decision-makers. Support the Process Hazards Analysis process for new projects and Unit Revalidations.
5. Execution Support & Field Coordination: Support project commissioning and startup including equipment inspection, operating procedure updates and development, training, startup assistance and project post-audit.
6. Collaboration, Mentoring & Knowledge Sharing: Mentor process engineers in areas of expertise. Collaborate with operations, maintenance, reliability, safety, and environmental teams to ensure effective and compliant process designs. Collaborates with the Process Engineering Leads as needed to support technical tasks. Participate in PBF corporate and/or TRC special project teams, initiatives and Turnarounds as assigned.
7. Digital Tools & Communication: Utilize digital tools (e.g., PI System, Seeq, HYSYS) for process troubleshooting, and optimization. Support and contribute to process modeling efforts, collaborating with the process engineering team to optimize and troubleshoot refinery operations. Prepare technical reports, documentation, and presentations to communicate project progress and recommendations. Utilize Aspen HYSYS (and other applicable simulation tools) to develop, tune, and maintain rigorous process models that enable unit optimization, troubleshooting, constraint identification, debottlenecking, evaluation of operational changes and capital projects, including support for design basis development and engineering studies.

JOB QUALIFICATIONS

• B.S. in Chemical Engineering.
• 5+ years of relevant petro chemical experience required, with some process design experience preferred.
• Project development experience in a refinery and/or chemical plant environment is required.
• Experience in using HYSYS or other process design software required.
• PSPPM or other PSV sizing software experience preferred.
• Demonstrated ability to lead multidisciplinary reviews and mentor junior engineers.
• Must have excellent verbal and written communication skills.
• Capable of interfacing with multiple departments to drive and steward common goals.
• Must be self-motivated, results oriented and schedule driven.

We thank all respondents for their interest in PBF Holding Company LLC (“PBF Energy”), however, only those selected for an interview will be contacted.

Please no phone calls or emails to any employee of PBF Energy about this requisition.

Placement agencies or recruiters need not respond.

All resumes submitted by search firms to any employee of PBF Energy via email, the Internet or in any method without a valid written search agreement will be deemed the sole property of PBF Energy.

No fee will be paid in the event the candidate is hired by PBF Energy as a result of the referral or through other means.

PBF Energy is an equal opportunity employer.

We are committed to creating a diverse, inclusive environment.

All qualified applicants will receive consideration for employment without regard to race, color, religious creed, sex, gender, gender identity or expression, sexual orientation, reproductive health decision making, national origin, ancestry, genetic information, physical or mental disability, medical condition, marital status, age, veteran and military status, or any other status protected by applicable law.

We are committed to providing reasonable accommodation as required by law.

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About Us

Welcome to PBF Energy (NYSE: PBF), one of the largest independent petroleum refiners and suppliers of unbranded transportation fuels, heating oil, petrochemical feedstocks, lubricants and other petroleum products in the United States. Our subsidiaries own and operate refineries located in California, Delaware, Louisiana, New Jersey, and Ohio.

For more information on our companies, please visit our website at http://www.pbfenergy.com/.