Process Engineer – Fluid Catalytic Cracking (FCC)

About the Role

A leading organization in the refining and petrochemical sector is seeking an experienced Process Engineer – Fluid Catalytic Cracking (FCC) to provide technical leadership and operational support for FCC units across manufacturing facilities.

The successful candidate will be responsible for monitoring performance, optimizing operations, driving continuous improvement initiatives, and providing technical expertise in FCC technologies. This role offers the opportunity to work on complex refinery operations while contributing to operational excellence, process safety, and profitability improvements.

Key Responsibilities

• Conduct comprehensive performance assessments of FCC units and analyze key performance indicators (KPIs) related to yield, reliability, operability, profitability, and process safety.
• Develop benchmarking studies and present actionable recommendations to improve unit performance.
• Provide hands-on technical support for FCC optimization, troubleshooting, debottlenecking, revamps, and upgrades.
• Lead performance improvement programs aimed at increasing yield, reducing costs, enhancing reliability, and improving process safety.
• Facilitate benchmarking and best-practice sharing workshops across operating facilities.
• Develop and implement engineering standards, maintenance strategies, and operational best practices for FCC units.
• Provide technical support for engineering, procurement, and capital project activities.
• Coordinate with multidisciplinary teams including process, mechanical, electrical, and instrumentation engineers.
• Conduct technical audits and inspections to ensure compliance with safety, environmental, and quality standards.
• Evaluate and recommend advanced technologies, catalyst solutions, and process optimization strategies.
• Prepare technical reports, studies, and operational recommendations for management and stakeholders.
• Participate in business planning and support investment decisions related to FCC assets.
• Develop and deliver technical training programs related to FCC operations and optimization.
• Support incident investigations and root cause analysis activities involving FCC technologies.

Qualifications

Education

• Bachelor's Degree in Chemical Engineering.
• Master's Degree or advanced qualification is preferred.

Experience

• Minimum 15 years of experience within refinery operations.
• At least 10 years of direct hands-on experience in FCC operations, troubleshooting, and optimization.
• Proven track record of delivering measurable improvements in FCC performance, including yield enhancement, energy efficiency, reliability, and operational excellence.

Technical Requirements

• Comprehensive knowledge of FCC processes, equipment, and systems.
• Strong expertise in:
  • FCC reactor and regenerator operations
  • Catalyst management and performance optimization
  • Product fractionation systems
  • Process troubleshooting and root cause analysis
• Deep understanding of FCC catalyst chemistry and catalyst selection strategies.
• Experience addressing operational challenges such as:
  • Afterburn
  • Catalyst circulation issues
  • Product quality deviations
  • Reliability and performance constraints
• Proficiency in process simulation and modeling software such as:
  • Aspen HYSYS
  • KBC Petro-SIM
• Strong understanding of refinery economics and FCC contribution to overall refinery profitability.
• Familiarity with relevant industry standards and regulations, including API and ASME standards.