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 one hour. The worker is subject to extreme heat: Temperatures above 100 degrees F for periods of more than one hour. The worker is subject to noise: There is sufficient noise to cause the worker to shout in order to be heard above the ambient noise level. The worker is subject to hazards: Includes a variety of physical conditions, such as proximity to moving mechanical parts, electrical current, working on scaffolding and high places, exposure to high heat or exposure to chemicals. The worker is subject to atmospheric conditions: One or more of the following conditions that affect the respiratory system or the skin: fumes, odors, dusts, mists, gases, or poor ventilation. The worker is subject to oils: There is air and/or skin exposure to oils and other cutting fluids. The worker is required to wear a respirator. The worker is required to don a gas mask. Inside: Sedentary Work: Exerting up to 10 pounds of force occasionally and/or a negligible amount of force frequently or constantly to lift, carry, push, pull or otherwise move objects, including the human body. Sedentary work involves sitting most of the time. Subject to inside environmental conditions: Protection from weather conditions, but not necessarily from temperature changes Employee must have the ability to see written documents, computer screens, and to adjust focus. Hearing: Perceiving the nature of sounds at normal speaking levels with or without correction. Ability to receive detailed information through oral communication and to make discriminations in sound. Performance Indicators Following are the Primary Key Performance Indicators for this position: Achieve SHE metric targets for safety and environmental incidents Meet or exceed plant production goals Meet or exceed production supply reliability AsCare, 20P, MOC/PSM compliance achieved Meet or exceed first pass prime Meet or below budget for Dow assets Meet or exceed efficiency targets Completion of assigned action items Achieve plant department and personal metrics as defined in annual performance assessment. Equal Employment Opportunity Statement INEOS Oxide is an equal opportunity employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, gender identity, sexual orientation, national origin, disability status, or protected veteran status. We strive to ensure equal opportunity for all employees and applicants and make hiring decisions based on qualifications, merit, and business needs. E-Verify INEOS Oxide participates in E-Verify. E-Verify is a system that allows employers to verify the employment eligibility of their employees in the U.S. All new hires at INEOS will be required to confirm their identity and employment authorization through E-Verify. Our culture is one of honesty and integrity with an emphasis on safety, health and environmental performance. On our team, people are acknowledged for embracing new practices that help create real value for customers.