Senior Process Engineer

Senior Process Engineer – Cryogenic NGL Recovery Specialist

Company: Melland Engineering & Consulting
Location: Houston, TX (In Office, 25% travel to West Texas required)
Employment Type: Full-Time
Experience Level: 5-10 years
Salary: Commensurate with Experience

Position Summary

We are seeking a Senior Process Engineer with deep, hands-on experience in Cryogenic NGL recovery and natural gas processing facilities. This role requires strong operational and engineering expertise in cryogenic gas plants, with ownership of troubleshooting, optimization, and debottlenecking of NGL recovery systems.

The ideal candidate will act as a technical authority for cryogenic gas processing performance, driving improvements in recovery efficiency, reliability, and plant throughput.

Must-Have Experience

  • Direct experience with Cryogenic NGL recovery plants (required)
  • Strong background in natural gas processing, turboexpander systems, or cryogenic gas fractionation
  • Proven experience in plant troubleshooting, optimization, and debottlenecking
  • Hands-on experience with Aspen HYSYS and/or UniSim
  • Strong understanding of:
    • Heat & material balances
    • Refrigeration cycles
    • Gas separation processes

Key Responsibilities

Cryogenic Process Engineering

  • Develop and validate process deliverables including:
    • PFDs and P&IDs
    • Heat & material balances
    • Hydraulic and equipment sizing calculations
    • Process datasheets and operating cases
  • Perform process simulation and performance modeling using Aspen HYSYS / UniSim
  • Analyze cryogenic system behavior including turboexpander and JT valve performance

Plant Optimization & Operations Support

  • Lead troubleshooting of cryogenic NGL recovery units and gas processing facilities
  • Identify opportunities to improve:
    • NGL recovery efficiency
    • Plant throughput and reliability
    • Energy and refrigeration system performance
  • Support commissioning, startup, and stabilization of cryogenic plants
  • Work directly with operations to resolve performance issues in real time

Technical Leadership

  • Serve as technical authority for cryogenic process design and plant performance
  • Review engineering deliverables for accuracy, operability, and process integrity
  • Provide technical guidance to junior engineers and multidisciplinary teams
  • Ensure process design intent is maintained across engineering disciplines

Project Execution & Coordination

  • Manage multiple complex cryogenic and gas processing projects simultaneously
  • Coordinate across mechanical, instrumentation, and operations teams
  • Ensure alignment of scope, schedule, cost, and technical objectives
  • Communicate with project managers, clients, and field operations teams

Standards, Quality & Continuous Improvement

  • Apply and improve engineering standards for gas processing and cryogenic systems
  • Ensure compliance with engineering codes and company quality systems
  • Drive continuous improvement initiatives focused on plant performance
  • Communicate technical findings and recommendations to leadership

Client & Field Interface

  • Interface directly with clients and operating teams to understand plant constraints
  • Translate operational issues into engineering solutions
  • Support business development and technical discussions when required

Ideal Candidate Profile

  • Senior-level process engineer with strong cryogenic gas plant experience
  • Strong field exposure in gas processing operations
  • Skilled in troubleshooting and improving live plant performance
  • Comfortable bridging operations and engineering teams
  • Strong communicator with operators, engineers, and clients

What We Offer

  • Competitive salary based on experience and qualifications.
  • Comprehensive benefits package, including health, dental, and vision insurance, 401(k), and paid time off.
  • Opportunities for professional growth and development in the natural gas industry.
  • A collaborative and innovative work environment with exposure to cutting-edge projects.
  • Support for new graduates through mentorship and hands-on training.

How to Apply

If you’re passionate about advancing your career in natural gas engineering, we’d love to hear from you! Please submit your resume and a cover letter to resume at mellandconsulting dot com with the subject line “Senior Process Engineer Application – [Your Name].”

Melland Engineering & Consulting is an equal opportunity employer.