Senior Process Development Engineer

Placements24; Pietermaritzburg; Hybrid; ZAR 900,000 - 1,500,000; Full time

Job summary

Placements24 seeks aSenior Process Development Engineer in Pietermaritzburg to lead the design, optimization, and scale-up of advanced chemical processes. The role bridges lab research and industrial production, focusing on safe, efficient, and sustainable operation, with collaboration across R&D, operations, and QA teams.

The candidate will develop process models, perform PHAs, and drive technology transfer to production, while mentoring junior engineers and delivering robust technical

Qualifications

• Bachelor's or Master's degree in Chemical Engineering from an accredited institution.
• 7+ years of progressive experience in process development, design and scale-up in the chemical manufacturing industry.
• Experience with process simulation software (Aspen Plus, HYSYS).
• Strong understanding of unit operations, reaction kinetics, thermodynamics, and separation processes.
• Demonstrated experience in PHAs and implementing safety measures.
• Excellent analytical, problem-solving and critical thinking skills.
• Proficiency in data analysis and statistical process control (SPC).
• Effective communication and interpersonal skills.

Responsibilities

• Lead the development and optimization of chemical processes from conceptualization through pilot plant and commercial scale-up.
• Conduct rigorous PHAs and implement safety protocols to ensure compliance with regulatory standards.
• Design and execute experiments to evaluate process parameters, identify critical control points, and troubleshoot operational issues.
• Develop mass and energy balances, PFDs and P&IDs for new and existing processes.
• Collaborate with engineering and operations teams to ensure successful technology transfer and implementation.
• Analyze process data to identify areas for improvement in yield, efficiency, cost reduction, and environmental impact.
• Prepare detailed technical reports, presentations, and documentation for internal stakeholders and regulatory bodies.
• Mentor junior engineers and provide technical guidance on process design and optimization challenges.

Skills

Process development

Scale-up

PHAs

Data analysis

SPC

Communication

Education

Bachelor's or Master's in Chemical Engineering

Tools

Aspen Plus

HYSYS

Job description

About the Role

Our client, a leading innovator in specialty chemicals, is seeking a highly skilled and experienced Senior Process Development Engineer to join their dynamic team in Pietermaritzburg, KwaZulu-Natal. This is an exciting opportunity to contribute to the design, optimization, and scaling of cutting‑edge chemical processes that drive product innovation and manufacturing excellence. You will play a crucial role in bridging the gap between laboratory‑scale research and full‑scale industrial production, ensuring efficient, safe, and sustainable operations. The role involves significant hands‑on work, problem‑solving, and collaboration with cross‑functional teams, including R&D, operations, and quality assurance.

Key Responsibilities

• Lead the development and optimization of chemical processes from conceptualization through to pilot plant and commercial scale-up.
• Conduct rigorous process hazard analyses (PHAs) and implement safety protocols to ensure compliance with all regulatory standards.
• Design and execute experiments to evaluate process parameters, identify critical control points, and troubleshoot operational issues.
• Develop mass and energy balances, PFDs (Process Flow Diagrams), and P&IDs (Piping and Instrumentation Diagrams) for new and existing processes.
• Collaborate with engineering and operations teams to ensure successful technology transfer and effective implementation of new processes.
• Analyze process data to identify areas for improvement in yield, efficiency, cost reduction, and environmental impact.
• Prepare detailed technical reports, presentations, and documentation for internal stakeholders and regulatory bodies.
• Mentor junior engineers and provide technical guidance on process design and optimization challenges.

Requirements

• A Bachelor's or Master's degree in Chemical Engineering from an accredited institution.
• A minimum of 7 years of progressive experience in process development, design, and scale-up within the chemical manufacturing industry.
• Proven experience with process simulation software (e.g., Aspen Plus, HYSYS).
• Strong understanding of unit operations, reaction kinetics, thermodynamics, and separation processes.
• Demonstrated experience in conducting Process Hazard Analyses (PHAs) and implementing safety measures.
• Excellent analytical, problem‑solving, and critical thinking skills.
• Proficiency in data analysis and statistical process control (SPC).
• Effective communication and interpersonal skills, with the ability to collaborate across diverse teams.
• Experience with projects in the Pietermaritzburg area or similar industrial environments is advantageous.

Benefits

• Our client offers a comprehensive benefits package designed to support your well‑being and professional growth.
• This includes competitive remuneration, a performance-based bonus structure, comprehensive health insurance, retirement savings plan, ongoing professional development opportunities, and a supportive work environment that fosters innovation and collaboration.
• You’ll have the chance to work on challenging and rewarding projects that make a real impact.