Senior Process Engineer

Flint Hills Resources; Katy (TX); On-site; USD 120,000 - 190,000; Full time

Job summary

Optimized Process Designs (OPD), a Koch company, seeks a Senior Process Engineer to lead midstream and downstream oil & gas projects. You will drive scope, design, and construction, owning process simulations and equipment sizing while mentoring junior staff at OPD's Katy, TX headquarters.

The role emphasizes hands-on reactor/processor design within refinery or gas processing facilities, collaborating across disciplines and delivering high-impact results onsite.

Qualifications

• Experience in midstream or downstream oil & gas projects.
• Hands-on with process simulators (HYSYS, Unisim, etc.).
• Experience preparing equipment datasheets and sizing PSVs/Control valves.

Responsibilities

• Provide technical expertise across all project phases from scope through construction.
• Lead process engineering on multiple projects with support from other engineers.
• Mentor junior engineers to accelerate technical development.
• Independently evaluate and design facilities for midstream and downstream projects.
• Perform basic and detailed design activities for refineries and gas processing facilities.
• Own process deliverables: simulations, design calculations, equipment sizing/selection.
• Review client documents, FEED calculations, PFDs, P&IDs, datasheets, heat/mass balances, and line sizing.

Skills

Process engineering

Process simulation

Equipment datasheets

PSV sizing & control valves

Mentoring/junior engineers

Education

Bachelor's degree in Chemical Engineering

Professional Engineer license

Tools

HYSYS

Unisim

Job description

Optimized Process Designs, LLC (OPD), a Koch company, is seeking Senior Process Engineer to join our team and take a lead role in delivering midstream oil and gas projects. In this position, you will apply your technical expertise across all project phases, from initial scope development through detailed design and construction.

You will lead process engineering efforts, mentor junior engineers, and take ownership of critical process deliverables including simulations, design calculations, and equipment selection. The ideal candidate will have hands‑on experience with process simulation software, a strong background in refinery or gas processing facility design, and a passion for mentoring and collaborative problem‑solving. If you have a foundation in process engineering with a focus on midstream or downstream sectors, we invite you to contribute to complex, high‑impact projects that drive operational excellence.

This role will sit on-site Monday - Friday at OPD’s headquarters in Katy, TX.

This role is not open to Visa sponsorship.

Our Team

At OPD, our people are our greatest asset. Through our people, we have developed a strong, contribution motivated, team with a reputation for honesty, integrity, and ability to successfully execute projects. We have a key advantage in being able to supply in-house construction services as well as in-house engineering/procurement. This enables clients to have a ''one stop shop'' for the overall project, providing increased efficiency and avoiding potential interface problems. OPD's industry experience, flexibility, and personal attention have made us a preferred partner to our customers and our tight knit, highly productive, team atmosphere makes OPD a great place to work.

What You Will Do

• Provide technical expertise to projects in all phases of work from initial project scope development through construction
• Lead process engineering on multiple projects with assistance from other Process Engineers
• Mentor junior engineers to help accelerate their technical advancement
• Independently evaluate and design facilities for midstream and downstream projects
• Basic & detailed design engineering activities for the assigned project in refineries and gas processing facilities
• Be the technical owner on all process deliverables such as - performing process simulations, design calculations, sizing & selection of equipment, etc
• Review of client's documents, specifications, datasheets, verification of FEED design & calculations, PFD, P&IDs, equipment datasheets, heat material balance, process line sizing calculations, hydraulic calculations, instrument datasheets including control valves and relief valves, and other process design-related tasks
• Evaluate vendor quotes and develop equipment bid tabs
• Assist in the development of I/O lists, line lists, cause & effect, control philosophies, shutdown philosophies, and providing necessary engineering inputs to the other disciplines
• Assist in developing start-up and operating manuals, attend and assist in Process Hazard Analysis meetings for projects, and attend start-ups for plants when requested

Who You Are (Basic Qualifications)

• Process engineering experience in midstream or downstream oil and gas industries.
• Working knowledge of process simulator software (ex: HYSYS, Unisim, etc.)
• Experience preparing equipment datasheets for heat exchangers, pumps, vessels, compressors, fired heaters, electric heaters, and distillation columns
• Experience in sizing PSVs and Control valves

What Will Put You Ahead

• Bachelor's degree or higher in Chemical Engineering
• Professional Engineer license

Hiring Philosophy

All Koch companies value diversity of thought, perspectives, aptitudes, experiences, and backgrounds. We are Military Ready and Second Chance employers. Learn more about our hiring philosophy here.

Who We Are

As a Koch Engineered Solutions company, Optimized Process Designs (OPD) provides clients with detailed engineering packages in all disciplines, single-point procurement for all equipment and materials, fabrication and direct-hired construction services throughout the United States. We leverage in-house capabilities and provide services with faster speed to market to help deliver increased cost savings while minimizing risk.

At Koch, employees are empowered to do what they do best to make life better. Learn how our business philosophy helps employees unleash their potential while creating value for themselves and the company.

Our goal is for each employee, and their families, to live fulfilling and healthy lives. We provide essential resources and support to build and maintain physical, financial, and emotional strength - focusing on overall wellbeing so you can focus on what matters most. Our benefits plan includes - medical, dental, vision, flexible spending and health savings accounts, life insurance, ADD, disability, retirement, paid vacation/time off, educational assistance, and may also include infertility assistance, paid parental leave and adoption assistance. Specific eligibility criteria is set by the applicable Summary Plan Description, policy or guideline and benefits may vary by geographic region.

Additionally, everyone has individual work and personal needs. We seek to enable the best work environment that helps you and the business work together to produce superior results.

Equal Opportunity Employer, including disability and protected veteran status. Except where prohibited by state law, some offers of employment are conditioned upon successfully passing a drug test. This employer uses E-Verify.