Sr. Process Engineer

About the Company

Our client is a company redefining the rules of sustainable manufacturing. They deliver traceable, mass-balanced circular solutions for the rubber, plastics, and petrochemical sectors — transforming end-of-life tires into high-value materials used by global brands across more than 3,000 applications. With proven technology, a strong commercial track record, and rapid global growth, this company leads the industry in circularity at scale. Executives join for the mission and stay for the people. The team has a bold, collaborative culture driven to make a difference.

Position: Senior Process Engineer

Location: Carmel, IN

Type: Full-Time

We’re seeking a Senior Process Engineer to lead the process design and optimization of pyrolysis operations—including reactors, heavy oil condensing, and carbon finishing systems. You’ll play a pivotal role in both greenfield and brownfield projects while supporting the development of operations, technical services, and training infrastructure.

Key Responsibilities

• Lead the end-to-end process design of pyrolysis plants.
• Design and optimize pyrolysis reactors and oil condensing systems.
• Review and approve FEED and EPC deliverables for brownfield projects.
• Prepare Basic Engineering Packages (BEP) for upcoming greenfield projects.
• Standardize process design documentation across facilities.
• Create and maintain process documentation: PFDs, P&IDs, mass and energy balances, data sheets, RFQs, etc.
• Utilize process simulation software (e.g., Aspen HYSYS, HTRI) for modeling and optimization.
• Define and monitor KPIs to evaluate process efficiency and project success.
• Support commissioning, startup, and troubleshooting for new and existing systems.
• Develop operating manuals, technical training materials, and QA/QC procedures.
• Collaborate across teams: Operations, Maintenance, Finance, Projects, and with external EPCs and vendors.
• Ensure compliance with safety and industry standards (ASME, ASTM, API, TEMA).
• Drive MOC (Management of Change) processes and documentation.

What You’ll Bring

• Bachelor’s degree in Chemical Engineering.
• 12+ years of experience in process design and development in oil & gas, gasification, or pyrolysis.
• Expertise in process modeling and simulation software (e.g., HYSYS, Aspen, HTRI).
• Proven experience with heat exchangers, condensing systems, pumps, and control valves.
• Strong understanding of PFDs, P&IDs, and process control strategies.
• Experience with EPC environments and process scale-up.
• Familiarity with relevant codes and industry standards.
• Exceptional communication, documentation, and problem-solving skills.
• Ability to lead complex projects and collaborate in multidisciplinary teams.

Why Apply?

From the Company

We offer a competitive benefits package designed to support your personal and professional growth:

• Career Growth: Training and development programs
• Employee Recognition: Real-time appreciation with personalized rewards
• Time Off: Generous PTO and paid sick leave
• Comprehensive Insurance: Medical, dental, and vision for employees and families
• Security: Short-term/long-term disability and life insurance at no cost to employee
• Retirement: 401(k) participation

Our Commitment to Inclusion

From the Company

We are an equal opportunity employer. We celebrate diversity and are committed to creating an inclusive environment for all employees—regardless of race, color, religion, age, gender identity, national origin, disability, veteran status, sexual orientation, or any other protected status.

Berkner Group has been retained to execute this search. If you were contacted by Berkner Group, please reply to the person who contacted you. If you are applying to a job posting, please email your resume and a brief introduction to ***email_hidden***. Please include your name and the title for this position ([Your name] - Sr. Process Engineer - Y667RR65) in the subject line of your email. We look forward to hearing from you!