Process Engineer

Fisher & Ludlow Div Of Harris Steel Ltd.; Louisiana, Northern (MO, KY); Hybrid; USD 110,000 - 140,000; Full time

Benefits offered by this job

Medical Insurance

401K and Profit sharing

Job summary

Nucor is seeking a Senior Chemical/Energy Engineer to lead advanced process development for decarbonization and Direct Reduction Iron (DRI) projects. You will design, analyze, and optimize chemical processes, develop digital twin models, and drive improvements using state-of-the-art simulation tools.

Responsibilities include leading HAZOP studies, ensuring regulatory compliance, and collaborating with cross-functional teams.

Qualifications

• Bachelor's degree in Chemical or Energy Engineering and 3 years of relevant experience.
• Experience designing and optimizing chemical processes for hydrogen-rich gas streams.
• Experience with decarbonization, digital twins, and process simulation tools.

Responsibilities

• Lead process development for decarbonization and Direct Reduction Iron (DRI) processes.
• Develop digital twin models for Tenova HYL technology used in DRI making.
• Design and optimize control strategies, mass and energy balances for complex systems.
• Ensure compliance with ASME, TEMA, API codes and safety programs.

Skills

Process optimization

Thermodynamics

Hydrogen-rich gas analysis

Safety and compliance

Education

Bachelor's degree in Chemical or Energy Engineering

Tools

Aspen Plus

Aspen HYSYS

ProMax

HAZOP methodology

Job description

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Welcome to Nucor, where our unique culture sets us apart. Joining Nucor means becoming part of North America's largest steel and steel products manufacturer, offering unmatched career opportunities and stability. We are known for our innovative sustainability practices and are the continent's largest recycler. Our vibrant culture, built on personal connections and teamwork, empowers every team member with the freedom to innovate and contribute to our collective success. Experience a workplace where safety, efficiency, and meaningful personal connections define every day, enriching both our teammates and the communities we serve.

• Nucor supports its teammates with top-tier benefits like Medical, Dental, Vision, and Disability Insurance, 401K and Roth accounts, Profit sharing, Pay-for-performance bonuses, Paid parental leave, Tuition reimbursement, Stock program, Scholarships and more.

Basic Job Functions:

Safety is the most important part of all jobs within Nucor; therefore, candidates must be able to demonstrate the ability to initiate, lead, and uphold safety policies, practices, procedures, and housekeeping standards at all times.

Lead process development activities for a sustainable future, decarbonization of the direct reduction process, the usage of iron oxides more efficient, research and propose new ways to obtain metallic iron. Design, analyze, and optimize efficient chemical processes for combustible and hydrogen-rich gas streams utilizing energy, kinetics, and heat transfer principles. Analyze hydrogen-rich gas systems and develop thermodynamic simulations to establish equilibrium variances for decarbonization strategies. Design and optimize HYL/Energiron direct reduction reactor, defining iron oxide throughput, reduction degrees, and metallization targets through detailed mass and energy balances. Develop digital twin models of Tenova HYL technology for Direct Reduction Iron (DRI) making processes utilizing Aspen Plus, Aspen HYSYS, and ProMax. Optimize oxygen injection lances for the partial combustion system in the transfer line, a critical control point of the Tenova HYL process. Engineer lance geometry, flow distribution, and injection dynamics to precisely regulate O delivery and drive controlled methane reforming for H and CO generation. Ensure stable partial oxidation conditions by preventing over combustion, protecting downstream equipment. Review and ensure compliance of complex chemical conditions for critical thermal equipment, pressure vessels, fire systems, and gas handling in accordance with international codes/standards ASME, TEMA, and API. Develop the complete automatic operation and control strategy for a SulFerox (iron-chelate liquid redox) HS removal unit, scavengers, filtration system, chemical dosing establishing the layout for the equipment, slurry handling circuits. Design control loops that optimize HS removal efficiency, system stability and solids management to comply with the government regulations using advanced mass transfer and thermodynamics. Lead systematic identification of process hazards and operability (HAZOP) risks associated with methane reformers, HYL reduction reactors, gas handling systems, CO/H circuits, pressure vessels, heaters, auxiliary systems, and amine systems. Optimize temperature profiles and residence times within the Tenova HYL reactor by evaluating endothermic reduction zones, carbon deposition thresholds, and sticking limit boundaries to enhance productivity, minimize natural gas consumption ratios, and ensure stable metallization performance. Lead multi-disciplinary capital projects such as process safety and equipment upgrades. Stay current with new process technologies, tools, design practices, methods, and concepts. Train and develop others. Up to 20% international and domestic travel required for meetings, trainings, and consultations with other divisions/factories.

Minimum Qualifications:

Candidate must have a Bachelor's or foreign equivalent degree in Chemical or Energy Engineering and 3 years of experience in designing, analyzing, and optimizing efficient chemical processes for combustible and hydrogen-rich gas streams utilizing energy, kinetics, and heat transfer principles. Must have experience in: Analyzing hydrogen-rich gas systems and developing thermodynamic simulations to establish equilibrium variances for decarbonization strategies. Developing digital twin models of Tenova HYL technology for Direct Reduction Iron (DRI) making processes utilizing Aspen Plus, Aspen HYSYS, and ProMax. Leading systematic identification of HAZOP risks associated with methane reformers, HYL reduction reactors, gas handling systems, CO/H circuits, pressure vessels, heaters, and auxiliary systems. Reviewing and ensuring compliance of complex chemical conditions for critical thermal equipment, pressure vessels, fire systems, and gas handling in accordance with international codes/standards ASME, TEMA, and API. Up to 20% international and domestic travel required for meetings, trainings, and consultations with other divisions/factories.

Preferred Qualifications:

Nucor is an Equal OpportunityEmployer and a drug-free workplace