Senior Process Engineer

BIOFerm; Madison (WI); On-site; USD 110,000 - 150,000; Full time

Job summary

BIOFerm, a Wisconsin-based renewable energy company, seeks a Senior Process Engineer to lead the design of anaerobic digestion and biogas upgrading facilities from concept through start-up. This role requires cross-functional leadership, mentoring, and hands-on project execution in Madison, WI.

The ideal candidate will command strong process engineering fundamentals, drive design reviews, and collaborate with PM, BD, Construction, and Commissioning teams.

Qualifications

• Bachelor's degree in Chemical or Mechanical Engineering; master's preferred.
• 5+ years in progressive process engineering, with anaerobic digestion or biogas exposure.
• Strong leadership, mentoring, and cross-functional collaboration.
• Experience from concept through start-up on multi-project environments and travel up to 25%.

Responsibilities

• Lead process design for anaerobic digestion and biogas projects.
• Review and mentor other engineers; set scope and schedules.
• Lead permitting, vendor relations, and design reviews.
• Coordinate with project team and other departments.
• Support construction and commissioning, start-up testing.
• Lead process safety reviews (PHA/HAZOP) and formal design reviews.

Skills

Process design

Project leadership

Mentoring

Mass balances

PFDs & P&IDs

Process safety

AutoCAD

Engineering leadership

Analytical skills

Renewable energy

Education

Bachelor's degree in Chemical or Mechanical Engineering

Master's degree preferred

PE license preferred

Tools

AutoCAD

Process simulation

ERP systems

Job description

BIOFerm, a Wisconsin-based renewable energy company, is currently looking for a Senior Process Engineer. We specialize in turnkey anaerobic digestion and biogas upgrading facilities. Our mission is to provide sustainable, economical solutions for organic waste diversion by transforming food waste, manure, biosolids, and other organic materials into renewable natural gas (RNG), green energy, vehicle fuel, heat, and organic products.

Position Overview

The Senior Process Engineer leads the process design of BIOFerm's anaerobic digestion and biogas upgrading facilities from concept and permitting through construction, commissioning, and start-up. This role sets engineering scope and schedules, reviews other engineers' work, and partners with Project Management, Business Development, Construction, and Commissioning. The ideal candidate will combine deep process expertise with hands‑on project experience and strong technical leadership, including mentoring other engineers. This is a full-time, on‑site role based in Madison, WI.

Key Responsibilities

• Own the process design package for assigned projects — project specifications, conceptual design, PFDs, mass and energy balances, equipment sizing calculations, P&IDs, and operation manuals — and ensure it meets client requirements, applicable codes, and company design standards.
• Drive optimization of equipment and facility performance, including root‑cause analysis of underperforming assets and development of corrective design changes.
• Prepare and approve design outputs, datasheets, and drawings, and serve as technical reviewer of design work produced by other engineers.
• Lead the permitting process, including agency interface and preparation of technical submittals.
• Establish and manage vendor relationships, develop technical specifications, evaluate bids, and lead technical negotiations with suppliers.
• Submit purchasing requests with equipment specs in company’s system.
• Serve as the lead process engineering contact to the Project Team and other department engineers, setting engineering scope, sequence, and deliverable schedules to facilitate smooth progress of engineering work.
• Review and approve the final plant/process design.
• Advise the Project Manager on design modifications during construction, including technical, cost, and schedule impact.
• Support the Construction Team during construction phase and carry out site checks.
• Support the Commissioning Team during plant start‑up.
• Conduct tests and monitor the process performance.
• Lead troubleshooting and resolution of complex process problems escalated from projects and operating plants.
• Evaluate processes and equipment to ensure compliance with environmental, safety, and quality standards.
• Assemble reports and document processes.
• Support the operation engineering team.
• Lead cross‑functional teams.
• Evaluate and recommend new processes, technologies, and equipment, and lead their introduction into the standard design.
• Partner with Business Development on project development, technical proposals, schedules, and budgets.
• Perform and validate process design and simulations for major plant components.
• Mentor and provide technical guidance to less experienced engineers, including review and checking of their calculations, datasheets, and drawings.
• Develop and maintain process design standards, calculation templates, and engineering best practices, and drive their adoption across projects.
• Lead process safety reviews (PHA/HAZOP) and ensure resulting action items are closed in the design.
• Serve as a technical authority in client‑facing meetings and design reviews.
• Perform other tasks and special projects as may be assigned.

Qualifications & Skills

• Bachelor's degree in Chemical or Mechanical Engineering required; master's degree preferred.
• 5+ years of progressive process engineering experience, including design experience in anaerobic digestion, biogas, renewable natural gas, refining, petrochemicals, or gas processing.
• Strong technical abilities and analytical skills.
• Excellent written and verbal communication skills.
• Proven ability to identify, assess, and solve problems.
• Demonstrated technical leadership, including mentoring engineers, leading design reviews, and influencing without formal authority.
• Strong organizational skills, documentation skills, and attention to detail.
• Self‑motivated, goal‑oriented, able to work independently in a dynamic environment.
• Ability to set priorities, meet deadlines, and manage time in a fast‑paced, changing environment.
• Demonstrated proficiency with process simulation and engineering analysis software, AutoCAD or comparable P&ID tools, and ERP systems.
• Expert command of process engineering fundamentals, including mass and energy balances, hydraulics, heat transfer, and equipment sizing.
• Willingness and desire to work as part of a multi‑disciplinary team on several tasks/projects.
• Excellent knowledge of renewable energy concepts and technologies.
• Working knowledge of applicable health, safety, and environmental regulations and of process safety practices such as PHA and HAZOP.
• Experience carrying projects from concept through detailed design, construction, commissioning, and start‑up.
• PE license preferred; EIT with demonstrated progress toward licensure a plus.
• Valid U.S. driver’s license and passport required.
• Willingness to travel (estimated up to 25% of the time).
• Must have authorization to work in the United States without current or future visa sponsorship from BIOFerm.

Compensation & Benefits We offer a competitive salary based on experience and a comprehensive benefits package.

Learn more about BIOFerm at BIOFermEPC.com .