Senior Process Control Engineer - Smelter Operations

Placements24; Benoni; On-site; ZAR 1,000,000 - 1,600,000; Full time

Benefits offered by this job

Relocation assistance

Job summary

Placements24 in Gauteng is seeking a Senior Process Control Engineer for a major metallurgical operation near Benoni. You will design, implement, and optimize DCS/SCADA/PLC control systems for high-temperature smelting to ensure safe and efficient production.

The role requires expert APC/MPC knowledge, hands-on experience with Honeywell Experion, DeltaV, or ABB 800xA, plus strong programming skills. You will mentor junior engineers and advance energy efficiency and safety compliance.

Qualifications

• Bachelor's degree in a relevant engineering field with strong emphasis on control systems.
• 8+ years of process control experience in heavy industry or metallurgical settings.
• Proven experience designing, implementing, and tuning APC solutions and DCS/SCADA projects.

Responsibilities

• Design, configure, and maintain DCS/PLC/SCADA systems for smelting processes.
• Develop and implement APC/MPC strategies to optimize performance and stability.
• Troubleshoot control system issues and implement corrective actions.
• Collaborate with process engineers to define control strategies and tune loops.
• Ensure safety through SIS-related activities and maintenance.

Skills

APC strategies

DCS/SCADA/PLC

MPC

Control system tuning

Programming (Python/C#/C++)

Troubleshooting

Leadership

Education

Bachelor's degree in Chemical/Electrical/Mechanical Engineering with control specialization

Tools

Honeywell Experion

Emerson DeltaV

ABB 800xA

Siemens PLC

Allen-Bradley PLC

Job description

About the Role

Our client, a major metallurgical processing company, is seeking a highly experienced Senior Process Control Engineer to join their advanced smelter operations near Benoni, Gauteng . This critical role involves the design, implementation, and optimization of complex process control systems to ensure the safe, efficient, and consistent production of high-quality metal products. The ideal candidate will possess a deep understanding of industrial automation, advanced process control (APC) strategies, and distributed control systems (DCS), specifically applied within a high-temperature smelting environment. We are looking for a proactive engineer who can leverage technology to enhance process stability, improve yields, and reduce operational costs. This is an outstanding opportunity to make a significant impact within a leading industrial facility in the Benoni, Gauteng region.

Key Responsibilities

• Design, configure, and maintain Distributed Control Systems (DCS), Programmable Logic Controllers (PLC), and Supervisory Control and Data Acquisition (SCADA) systems for smelting processes.
• Develop and implement Advanced Process Control (APC) strategies, including model predictive control (MPC), to optimize process performance and stability.
• Troubleshoot complex control system issues, diagnose faults, and implement effective corrective actions.
• Collaborate with process engineers and operators to define control strategies, tune loops, and improve overall process efficiency.
• Conduct process hazard analyses (PHA) related to control systems and implement necessary safety instrumented systems (SIS).
• Develop and maintain process control documentation, including P&IDs, logic diagrams, and operating procedures.
• Stay abreast of new technologies in industrial automation and process control, evaluating their potential application in smelter operations.
• Provide technical leadership and mentorship to junior control engineers and technicians.
• Ensure compliance with all relevant safety, environmental, and industry standards.
• Participate in project engineering for control system upgrades and new installations.
• Optimize energy consumption and resource utilization through effective control strategies.

Requirements

• A Bachelor's degree in Chemical Engineering, Electrical Engineering, or Mechanical Engineering with a strong specialization in control systems.
• A minimum of 8 years of experience in process control engineering, with significant exposure to heavy industrial or metallurgical processing environments, particularly smelting.
• In-depth knowledge and hands-on experience with major DCS platforms (e.g., Honeywell Experion, Emerson DeltaV, ABB 800xA) and PLC systems (e.g., Siemens, Allen-Bradley).
• Proven experience in designing, implementing, and tuning APC solutions.
• Strong understanding of process dynamics, thermodynamics, and chemical kinetics relevant to smelting.
• Proficiency in programming languages (e.g., C++, C#, Python) for control system development and data analysis is a plus.
• Excellent analytical, problem-solving, and diagnostic skills.
• Strong communication, teamwork, and leadership abilities.
• Experience working within the industrial landscape of Benoni, Gauteng is advantageous.
• Knowledge of functional safety standards (e.g., IEC 61508/61511) is highly desirable.

Benefits

Our client offers a highly competitive salary package, commensurate with experience, including annual performance bonuses and comprehensive benefits. These include excellent medical aid coverage, a substantial provident fund, and opportunities for continuous professional development and international training. The company fosters a collaborative and innovative work environment with clear pathways for career advancement. Relocation assistance may be provided for exceptional candidates moving to the Benoni, Gauteng area. Join a leading team at the forefront of metallurgical process control.