Production Engineer

Company:INEOS Oxide
Interested in joining a winning team? A team whose employees share in the ownership of the business and are empowered to make a difference?
Organizational Context and Job Purpose
INEOS Organization:
INEOS is a global manufacturer of petrochemicals and specialty chemicals, producing the raw materials that are essential in the manufacturing of a wide range of goods. The chemicals manufactured by INEOS enhance almost every aspect of modern life. INEOS is the 3rd largest petrochemical company in the world with 194 manufacturing sites across 29 countries and employing more than 26,000 people globally.
BUSINESS CONTEXT:
INEOS Oxide is one of the most diverse, dynamic and successful businesses within INEOS, operating 4 manufacturing sites in Europe and North America. These are located at Antwerp, Belgium; Koln, Germany; Lavera, France; Plaquemine, US. INEOS Oxide is one of the world’s leading producers of Ethylene Oxide (EO) and Ethylene Oxide Derivatives (EODs), producing a broad range of 200+ products spread across 4 key value chains – Ethylene Oxide; Propylene Oxide; Oxo-alcohols & Esters; ENB. The total EO production capacity is currently > 1 million mt and the total production capacity for the overall business is ~ 3.4 million mt.
Ethylene oxide (EO) is an important building block for the preparation of a wide variety of EO derivatives (EODs), including various surfactants, as well as many other chemical intermediates including Ethylene Glycols, Glycol Ethers, Polyethylene Glycols and Ethanolamine's.
In 2024 INEOS Oxide acquired a new site in Bayport (TX) and the respective business in the US, which increased the total production capacity of the business to ~ 4.4 million mt and through this acquisition INEOS Oxide has achieved a true global footprint, in particular for the Ethylene Oxide value chain.
Purpose of the Job:
The purpose of the role is to lead the improvement process of the Dow assets by gathering and analyzing data to identify and evaluate improvement opportunities. Collaborating with operations personnel to lead, the expectation is to provide ownership and drive results. This role will focus on evaluating and prioritizing gaps in current operations and knowledge-based solutions.
Environment / Context:
The candidate is responsible for safe and efficient operation of assigned production unit using established operating discipline and procedures. The Dow Asset Production Engineer is responsible for maintaining the plant assets and protective systems integrity and to deliver established production targets set by the business. They will identify and implement Process Improvements and will develop and enhance key process engineering competencies such as steady state modelling, dynamic modelling, specific unit operations design (e.g., Heat Exchange, Distillation), fluid dynamics calculations and others.
Responsibilities and Accountabilities
Accountability 1:
SHE
Most important activities
Maintain and control the safe and efficient operation of the production unit using established operating disciplines and procedures. Ensure safety and environmental compliance is achieved.
Responsible for maintaining the plant assets and protective systems integrity.
Assist in defining and maintaining the correct operating envelopes for the organization. Investigate when deviations outside of the operating envelopes occur.
Participate in the development of operating procedures and training materials.
Provide leadership in PSM and Environmental efforts including Process Hazard Analyses (PHAs), Management of Change process, Risk Assessments and incident investigations.
Input, evaluate and approve MOCs
Conduct PSSRs for MOCs
Participate in PHAs as the process engineering representative
Understand and lead by example for all safety and environmental programs.
Investigate all SHE incidents.
Routinely collect, report, and address SHE near misses.
Complete all assigned action items from PHAs, incidents, audits, etc. in a timely manner and keep status and plans for action items updated.
Maintain safety as the highest priority of the plant
Maintain the 20 Principles of Safety
Conduct routine AsCare tours and participate in audits.
Adhere to and uphold all safety policies and standards
Complete all responsibilities required as an Asset Engineer
Develop and maintain list of critical assets and protective systems
Develop and ensure compliance to a procedure for safety systems impairments/bypass
Define and maintain operating envelopes for the assets and review plant data regularly to investigate deviations outside of the safe operating envelop
Develop and maintain the MOC procedure
Identify and implement risk mitigation for all loss of containment scenarios
Accountability 2:
Manufacturing Excellence
Most important activities
Deliver established production targets for Dow asset while complying with quality specifications
Troubleshoot process problems with Production Specialists, Quality, Maintenance and operations teams.
Cross train and provide backup for the Production Engineer role for both Dow assets
Benchmark, identify and implement best in class improvements and practices to improve the operation and efficiency of the unit
Actively provide input and participate in operator development and training programs with operations and training personnel
Lead and/or participate in root cause investigations
Assist in identifying and closing performance gaps, which can include project development and execution
Provide data to validate that the projects deliver performance objectives after implementation.
Provide technical support and coach site personnel on measurements and updates of technology performance and asset utilization data.
Track unit efficiency and identify opportunities to optimize the operations of the plant to minimize cost and waste.
Identify key performance indicators and develop a monitoring process to ensure potential deviations are handled proactively.
Utilize engineering practices to understand plant bottlenecks and present solutions to increase plant capacity.
Be proficient in the proprietary Dow MOD V process control system to be able to troubleshoot and improve the process
Track production losses and first pass prime to identify opportunities for improvement and drive solutions to improve product supply reliability and first pass prime
Evaluate typical analytical data annually and update typical values as needed
Provide support to operations during upset conditions, start-ups and T/As. This includes serving as a back-up for the plant production specialist.
Attend meetings with Dow to understand their production needs as well as exchange information to enhance the continuous improvement process.
Utilize modelling software as needed to predict the performance of the various process equipment.
Support capital projects as the production representative.
Provide normal operating conditions
Provide maximum pressures/temperature/flows, etc. for equipment design
Skills/Competencies
Education/Experience
Bachelor of Science in Chemical Engineering
Minimum of 1 year plant process experience preferred
Technical Skills
Training Skills
Keen computer skills with knowledge of MS Office
Process modelling using Aspen software
Equipment sizing
PSV sizing
Knowledge of distillation column operations
Knowledge of PSM
Knowledge of hydraulics
Process troubleshooting
Behavioral Skills
Exceptional communication skills, both oral and written
Strong mechanical aptitude
Safety role model
Problem solving skills with data analysis ability
ADA Physical Requirements, Visual Acuity Requirements and Environmental Conditions
Outside
Light Work: Exerting up to 20 pounds of force occasionally, and/or up to 10 pounds of force frequently, and/or a negligible amount of force constantly to move objects
The worker is subject to inside environmental conditions: Protection from weather conditions, but not necessarily from temperature changes.
The worker is subject to outside environmental conditions: No effective protection from the weather.
The worker is subject to both environmental conditions: Activities occur inside and outside.
The worker is subject to extreme cold: Temperatures below 32 degrees F for periods of more than on