Process Engineer – Fluid Catalytic Cracking

Overview

We are seeking a Process Engineer with extensive hands-on expertise in Fluid Catalytic Cracking (FCC) processes to join the Downstream Operation Engineering Solutions Department (OESD).

OESD’s technical team provides high-quality, multi-disciplinary support to GM operating facilities (Refineries, NGLF, and petrochemical plants) within the Kingdom of Saudi Arabia and globally.

The primary role is to provide in-depth process engineering and operations expertise to monitor, optimize, and drive performance improvement programs for refineries’ FCC, including both remote and on-site technical advisory support, benchmarking, and technology knowledge management.

Key Responsibilities

As the successful candidate you will be required to perform the following:

• Conduct comprehensive performance reviews of existing FCC units, analyzing Key Performance Indicators (KPIs) related to yield, operability, profitability, reliability, and process safety. Develop and present quarterly benchmarking reports with actionable improvement recommendations.
• Lead benchmarking and best practices exchange workshops among Global Manufacturing facilities (wholly-owned and affiliates), facilitating knowledge sharing and continuous improvement in FCC technologies.
• Deliver on-demand remote and field technical advisory support, including troubleshooting, optimization, debottlenecking, revamp, and upgrade activities for FCC units. Provide detailed service reports for each support activity.
• Drive performance improvement programs that enhance process safety, optimize manufacturing costs, and increase FCC unit reliability and yield.
• Develop and implement best practices and standards for FCC engineering and maintenance, ensuring alignment with industry standards and regulations.
• Provide expert technical support to project teams and contractors for FCC engineering and procurement activities.
• Coordinate with other disciplines (mechanical, instrumentation, and electrical) to ensure optimal performance and integration of FCC equipment.
• Conduct regular audits and inspections of FCC equipment to ensure compliance with safety, environmental, and quality regulations and standards.
• Evaluate and recommend new technologies and innovations for FCC improvement and optimization, including catalyst developments and advanced control strategies.
• Prepare and update technical documentation and reports for FCC engineering and operation.
• Participate in business plan development and coordinate with stakeholders for capital investments in FCC facilities.
• Facilitate technical knowledge exchange workshops with FCC process technology licensors and Global Manufacturing facilities.
• Develop and deliver in-house technical training programs on FCC operations and optimization to Global Manufacturing facilities as needed.
• Participate in incident investigation activities concerning FCC process technologies as required by operating facilities.

Minimum Requirements

As a successful candidate you will hold a:

• Bachelor’s Degree in Chemical Engineering. An advanced degree is preferred.
• Minimum of 15 years of experience in refinery operations, with at least 10 years of hands-on experience specifically in FCC operations and optimization.
• Demonstrated ability to optimize FCC operations, with specific examples of performance improvements achieved (e.g., yield improvements, energy savings, reliability enhancements).
• Comprehensive knowledge of FCC processes, equipment, and systems, including regenerator operations, catalyst management, and product fractionation.
• Deep understanding of FCC catalyst chemistry and selection criteria for various feedstocks.
• Expertise in FCC troubleshooting, including analysis of operational issues such as afterburn, catalyst circulation problems, and product quality deviations.
• Proficiency in process simulation software specific to FCC modeling (e.g., Aspen HYSYS, KBC Petro-SIM).
• Strong knowledge of refinery economics and the impact of FCC performance on overall refinery profitability.
• Familiarity with relevant industry standards and regulations (e.g., API, ASME) applicable to FCC units.
• Excellent oral and written communication skills, with the ability to prepare and present technical reports to various audiences, including senior management.
• Strong problem-solving and decision-making skills, with the ability to work independently and collaboratively with multidisciplinary teams.
• Experience in mentoring junior engineers and operators in FCC operations and optimization techniques.
• Candidate with mostly project/design/operation experience will not be considered.