Job Purpose

To improve plant performance by optimizing chemical processes, enhancing productivity, reducing costs, and supporting process scale-up and plant modifications through application of engineering principles and modern process technologies.

Principal Accountabilities

1. Process Optimization & Efficiency

• Analyze batch and continuous processes to improve yield, cycle time, and operational efficiency.
• Identify process bottlenecks and implement improvements to reduce downtime and energy consumption.

2. Process Monitoring & Control

• Monitor key process parameters (temperature, pressure, kinetics, etc.) to ensure consistent and stable plant operations.
• Develop control strategies using DCS/SCADA to enhance automation and process reliability.

3. Cost Reduction & Resource Optimization

• Identify opportunities for reducing raw material and energy consumption to achieve cost savings.
• Evaluate waste generation and implement reduction initiatives to improve sustainability.

4. Engineering & Documentation

• Prepare and maintain engineering documents including PFDs, P&IDs, and mass balance sheets to support plant operations and modifications.
• Assist in development of batch sheets and SOPs to standardize plant operations.

Process Improvement & Scale-Up

• Work with Production, Quality, and R&D teams to ensure smooth plant operations and technology transfer.
• Support plant modifications, expansions, and new product scale-ups to achieve business growth objectives.
• Ensure adherence to process safety standards including PSM/HAZOP to maintain safe plant operations.

Major Challenges

• Handling variability in batch and continuous chemical processes.
• Balancing process optimization with safety, cost, and quality constraints.
• Managing scale-up from lab/pilot to commercial production.

Decisions

• Selection of process improvement strategies and control mechanisms.
• Recommendations on plant modifications and technology enhancements.
• Decisions regarding process parameter adjustments and optimization initiatives.

Interactions

Internal Clients

• Production / Operations Team
• R&D Team
• Quality Assurance & Quality Control
• Maintenance & Engineering

External Clients

• Technology consultants
• Equipment vendors
• Engineering service providers

Behavioural / Leadership Competencies

• Analytical Thinking - Ability to evaluate complex process data and identify optimization opportunities.
• Problem Solving - Ability to troubleshoot process issues and implement effective solutions.
• Collaboration & Teamwork - Ability to work with cross-functional teams including production, R&D, and engineering.

Knowledge

Educational Qualifications

Minimum Qualification: B.E. / B. Tech. – Chemical Engineering

Work Experience

5–10 years of experience in chemical manufacturing (batch or continuous processes preferred)

Functional Competencies

• Strong knowledge of chemical reaction engineering, thermodynamics, and fluid dynamics
• Hands-on experience with simulation tools (Aspen Plus, HYSYS, etc.)
• Experience with DCS/SCADA systems
• Knowledge of PFDs, P&IDs, and process safety (HAZOP, PSM)
• Understanding of GMP / ISO / regulatory compliance