Process Engineer I BuOH & AAA at Sasol

Purpose of Job

• The Process Engineer I is part of the Technical & Engineering support team for Acrylic Acid & Esters and Butanol plants and will report to the Process Engineering Lead for the area.  The Process/Chemical Engineer will support the Process Engineering strategy with respect to meeting production targets, providing process engineering technical support and identifying improvement opportunities while working within a diverse operational team.  Due to the nature of the plant processes, there are regular shutdowns and equipment inspections, and the incumbent must be willing and able (fit) to provide this type of operational and technical field support as part of the position. A more adventurous orientated person will find this position suitable.

Key Accountabilities

• Understand process design intent and use as a basis for monitoring of plant health, pro-active reporting on problem areas and identifying improvement areas.
• Monitor and interpret performance on technical drivers, levers and constraints taking upstream and downstream units into account
• Providing process engineering technical support on various operating units: problem solving, identifying improvement opportunities to optimize efficiency, energy usage, production output, product quality, unit cost, safety, plant integrity, reliability & availability
• Translate loss accounting into improvement plans
• Assimilate and contextualise data for input into improvement initiatives through technical investigations via the asset management process
• Implement improvement opportunities via plant test runs, initiatives or projects
• Contribute unit-specific technical input into compilation and execution of test-runs, trials, studies, improvement initiatives, and the daily assurance process.
• Develop and maintain operating envelope documents; Ensure value chain basic documentation and systems are in place and at required standard
• Prevent and resolve technical issues resulting in operation outside the operating envelope
• Define OWAP (Operate within agreed parameters) and optimum operating window; OWAP monitoring and deviation prevention on unit level and assurance that unit is optimally operated within agreed operating envelopes.
• Proactive risk identification for own business unit operations and contribute technical input into compilation of Volume Protection Plans (VPP); Monitor adherence to and effectiveness of VPP
• Analyse effectiveness of data (including yields provided for production planning and scheduling processes)
• Provide process engineering support and input for small project process design.  Deliver technical track and process related inputs required on smaller projects (tier 4/5) in accordance with sound established engineering principles and standards to satisfy business requirements.
• Provide technical support in the event of a shutdown to facilitate the completion of the shutdown within the planned timeframe and subsequent plant recommissioning.  Conduct shutdown inspections to ensure process integrity and functionality of equipment, and recommendations of improvement opportunities during shutdowns
• Provide support on catalyst and chemicals loading, unloading, and conditioning.
• Support start-up and commissioning of business unit.
• Give input and participate in Technical Engineering design reviews such as Hazops, PFD and MFD reviews, PDA’s, etc.
• Give inputs into production operating manuals, including start up and shutdown procedures as well as training manuals
• Ensure that process engineering fundamental tools are in place and relevant
• Provide support to Process Safety Management (PSM) studies, initiatives, and defined compliance plans. Actively identify process safety threats and deliver on mitigation plans
• Define and manage Process Safety Information (PSI).
• Compliance with Sasol internal guidelines & policies e.g. Management of Change (MOC) processes. Compliance: Understanding the rules, regulations, sanctions and other statutory requirements, guidelines and instructions relating to governing bodies and organizations, both internally and externally.
• Ensure appropriate governance is applied with regards to the process scope of work development
• Adhere to SHE strategy to achieve zero harm.

Formal Education

• Minimum university bachelor’s degree in chemical engineering.  Eg. BSc Eng. (Chem) or B Eng. (Chem).

Working Experience

• Experience: 3+ relevant years