Process Engineer

Basic Job Functions:

Safety is the most important part of all jobs within Nucor; therefore, candidates must be able to demonstrate the ability to initiate, lead, and uphold safety policies, practices, procedures, and housekeeping standards at all times.

Lead process development activities for a sustainable future, decarbonization of the direct reduction process, the usage of iron oxides more efficient, research and propose new ways to obtain metallic iron. Design, analyze, and optimize efficient chemical processes for combustible and hydrogen-rich gas streams utilizing energy, kinetics, and heat transfer principles. Analyze hydrogen-rich gas systems and develop thermodynamic simulations to establish equilibrium variances for decarbonization strategies. Design and optimize HYL/Energiron direct reduction reactor, defining iron oxide throughput, reduction degrees, and metallization targets through detailed mass and energy balances. Develop digital twin models of Tenova HYL technology for Direct Reduction Iron (DRI) making processes utilizing Aspen Plus, Aspen HYSYS, and ProMax. Optimize oxygen injection lances for the partial combustion system in the transfer line, a critical control point of the Tenova HYL process. Engineer lance geometry, flow distribution, and injection dynamics to precisely regulate O delivery and drive controlled methane reforming for H and CO generation. Ensure stable partial oxidation conditions by preventing over combustion, protecting downstream equipment. Review and ensure compliance of complex chemical conditions for critical thermal equipment, pressure vessels, fire systems, and gas handling in accordance with international codes/standards ASME, TEMA, and API. Develop the complete automatic operation and control strategy for a SulFerox (iron-chelate liquid redox) HS removal unit, scavengers, filtration system, chemical dosing establishing the layout for the equipment, slurry handling circuits. Design control loops that optimize HS removal efficiency, system stability and solids management to comply with the government regulations using advanced mass transfer and thermodynamics. Lead systematic identification of process hazards and operability (HAZOP) risks associated with methane reformers, HYL reduction reactors, gas handling systems, CO/H circuits, pressure vessels, heaters, auxiliary systems, and amine systems. Optimize temperature profiles and residence times within the Tenova HYL reactor by evaluating endothermic reduction zones, carbon deposition thresholds, and sticking limit boundaries to enhance productivity, minimize natural gas consumption ratios, and ensure stable metallization performance. Lead multi-disciplinary capital projects such as process safety and equipment upgrades. Stay current with new process technologies, tools, design practices, methods, and concepts. Train and develop others. Up to 20% international and domestic travel required for meetings, trainings, and consultations with other divisions/factories.

Minimum Qualifications:

Candidate must have a Bachelor’s or foreign equivalent degree in Chemical or Energy Engineering and 3 years of experience in designing, analyzing, and optimizing efficient chemical processes for combustible and hydrogen-rich gas streams utilizing energy, kinetics, and heat transfer principles. Must have experience in: Analyzing hydrogen-rich gas systems and developing thermodynamic simulations to establish equilibrium variances for decarbonization strategies. Developing digital twin models of Tenova HYL technology for Direct Reduction Iron (DRI) making processes utilizing Aspen Plus, Aspen HYSYS, and ProMax. Leading systematic identification of HAZOP risks associated with methane reformers, HYL reduction reactors, gas handling systems, CO/H circuits, pressure vessels, heaters, and auxiliary systems. Reviewing and ensuring compliance of complex chemical conditions for critical thermal equipment, pressure vessels, fire systems, and gas handling in accordance with international codes/standards ASME, TEMA, and API. Up to 20% international and domestic travel required for meetings, trainings, and consultations with other divisions/factories.

Preferred Qualifications: