We are seeking a highly experienced, hands-on process engineering leader to drive technical excellence, field execution, and project delivery across modular systems, separations, and revamp projects. This role focuses on process design, plant optimization, and field-based debottlenecking, with a strong emphasis on ethanol, refining, and industrial process systems.
A critical component of this role is on-site field engagement, including real-time data collection and performance analysis to diagnose issues and implement high-impact operational improvements.
Position is remote and will require travel to ethanol plants for field visits with approximately 50% and travel to RCM Thermal Kinetics headquarters in Buffalo NY.
Key Responsibilities
Technical Leadership
Serve as senior technical authority on:
Distillation & separations
Heat integration / preheat trains
Tower internals and mass transfer equipment
Lead development of:
Process simulations (Aspen, Pro/II, ChemCAD)
PFDs / P&IDs / heat & material balances
Equipment design and datasheets
Provide expert guidance on revamps, debottlenecking, and grassroots design.
Ensure engineering solutions are practical, cost-effective, and constructible.
Field Site Assessment & Ethanol Plant Optimization (Core Requirement)
Lead and personally execute on-site field assessments at ethanol production facilities.
Collect and validate real-time operating data, including:
Pressure profiles
Temperature surveys
Flow rates and compositions
Perform unit-level diagnostics across:
Distillation systems (beer column, rectifier, side strippers)
Dehydration systems (molecular sieves)
Evaporation systems (multi-effect evaporators, syrup concentration)
Conduct plant walkdowns and operator interviews to understand true operating conditions.
Develop baseline simulation models calibrated with field data.
Revamp scopes and detailed engineering deliverables
Support implementation and startup to ensure measurable performance improvements.
Project & Execution Oversight
Lead projects from concept ? design ? execution ? startup
Ensure alignment between:
Engineering deliverables
Fabrication and installation
Field conditions and constraints
Serve as technical lead on key projects ($1MM–$10MM+)
Drive:
Technical quality
Schedule adherence
Scope clarity and risk mitigation
Team Leadership & Capability Building
Lead and mentor a team of:
Process engineers
Design engineers
Build internal capabilities in:
Ethanol process systems
Field data collection and validation
Simulation-driven debottlenecking
Train engineers in:
Field troubleshooting techniques
Translating plant data into actionable engineering solutions
Product & Engineering Development
Support development and refinement of:
Modular distillation systems
Separation and heat transfer solutions
Revamp and optimization methodologies
Standardize engineering approaches and tools for repeatable, high-quality execution.
Collaborate with fabrication and operations teams to improve design for manufacturability and installation.
Qualifications
Required
B.S. in Engineering (required)
15+ years experience in:
Process engineering (distillation/separations)
Plant operations support, revamps, or project engineering
Demonstrated hands-on field experience, including:
Pressure and temperature surveys
Real-time data collection and validation
On-site troubleshooting and test runs
Deep expertise in:
Distillation, fractionation, and mass transfer
Heat exchangers and thermal systems
Ethanol plant systems (distillation, dehydration, evaporation strongly preferred)
Proficiency in:
Process simulation tools (Aspen, PRO/II, ChemCAD)
Developing heat & material balances and equipment designs
Preferred
B.S. in Chemical or Process Engineering
Direct experience with ethanol plant debottlenecking and optimization
Experience executing revamp projects driven by field data
Strong understanding of:
Tower internals and hydraulics
Heat integration and energy optimization
Ability to independently perform:
Site walkdowns
Data reconciliation and model validation
Experience with modular system design and implementation
Equal Opportunity Statement
RCM is an equal opportunity employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, disability, or status as a protected veteran.
Disclaimer
This job description is intended to describe the general nature and the level of the work being performed by the people assigned to this position. It is not intended to include every job duty and responsibility specific to the position. RCM reserves the right to amend and change responsibilities to meet business and organizational needs as necessary.
Seniority level
Mid-Senior level
Employment type
Full-time
Job function
Management and Manufacturing
Industries
Business Consulting and Services
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