Process Engineer

The Process Engineer is a key member of the ArcelorMittal Texas HBI Research & Development team. This role is responsible for evaluating and optimizing the direct reduction process through advanced data analysis, cross-functional collaboration, and technical innovation. The Process Engineer will drive process improvement initiatives with a strong focus on operational efficiency, reliability, digitalization, and long-term sustainability.

Tasks & Responsibilities:

- Monitor and analyze key process parameters such as metallization rate, carbon content, top gas utilization, NG/CO ratios, and reformer performance.

- Prepare and maintain process documentation including Standard Operating Procedures (SOPs), Process Flow Diagrams (PFDs), and mass and energy balances.

- Analyze operational data and trends to improve plant performance, reduce downtime, and enhance product quality.

- Lead process troubleshooting and root cause analysis for operational upsets or performance deviations.

- Support start-up, shutdown, and changeover procedures in coordination with production and maintenance teams.

- Collaborate with automation engineers to optimize DCS control strategies, alarm systems, and process stability.

- Work closely with mechanical and electrical engineering teams to enhance the efficiency and performance of critical equipment.

- Review and optimize control systems and instrumentation, including:

- Control valves and positioners

- Gas analysis systems

- Weight scale and dosing systems

- PLCs, RIOs, and auxiliary cabinets

- Limit switches, level switches, and pressure/temperature switches

- Pressure, flow, and temperature transmitters (via PDM software and HART communicator)

- Ensure data accuracy and integration between instrumentation, process historians, and reporting systems.

- Participate in or lead CAPEX and digital transformation initiatives, including model-based control systems and advanced analytics.

- Conduct regular walkthroughs and equipment assessments to ensure safe, efficient plant operations and identify areas for process innovation.

- Promote and ensure adherence to all safety and environmental policies and procedures.

- Support ArcelorMittal’s broader R&D goals, sustainability strategy, and continuous improvement culture.

- Ensure adherence to Safety and Environmental policies, procedures, and requirements, with a commitment to continuous improvement toward achieving a zero-harm and zero-environmental-impact workplace.

Qualifications:

- Bachelor’s or master’s degree in chemical engineering, Process Engineering, or a related field required.

- Strong knowledge of process control, industrial instrumentation, and automation systems.

- Proficient in the use and troubleshooting of instrumentation including:

- Pressure, flow, and temperature transmitters

- Gas analysis systems

- Weight scales and dosing systems

- Limit switches, level switches, pressure/temperature switches

- Experience with PLC/DCS systems (e.g., Siemens, ABB, Honeywell, Emerson) and motor/VFD drives.

- Familiarity with hydraulic and pneumatic systems and their integration with process equipment.

- Skilled in mass and energy balance development, process modeling, and real-time data analysis.

- Experience using tools such as PI System (OSIsoft), PDM software, HART communication, and process simulation platforms.

- Ability to read and interpret technical drawings, schematics, and PFDs (Process Flow Diagrams).

- Strong analytical and problem-solving skills with a high level of attention to detail.

- Excellent communication skills in English, both verbal and written; capable of producing high-quality reports and technical documentation.

- Demonstrated ability to work both independently and within cross-functional teams in a fast-paced, technically demanding environment.

- Deep commitment to safety, environmental responsibility, and continuous improvement.

- Must be able to walk long distances and stand and work for more than 2 hours in tough environmental conditions (high temperature, high humidity, noise, & dust), and withstand heights of up to 500 feet.

- Must have reliable transportation to and from job site.

- Must have or be able to obtain a TWIC-card.