Process Design Engineer Resume Examples & Templates for 2025
The U.S. Bureau of Labor Statistics projects approximately 1,100 openings for chemical engineers annually through 2034, with a median salary of $121,860 — yet many process design engineers struggle to translate their technical depth into resumes that clear applicant tracking systems. Process design engineer resumes occupy a unique niche: they must demonstrate mastery of process simulation, P&ID development, and capital project execution while also proving commercial awareness of yield improvements, energy reductions, and schedule adherence. Unlike general chemical engineering roles, a process design resume lives or dies on its ability to quantify the scale, scope, and outcome of every design deliverable.
Table of Contents
- Why This Role Matters
- Entry-Level Process Design Engineer Resume
- Mid-Level Process Design Engineer Resume
- Senior Process Design Engineer Resume
- Key Skills & ATS Keywords
- Professional Summary Examples
- Common Mistakes to Avoid
- ATS Optimization Tips
- Frequently Asked Questions
- Citations & Sources
Why This Role Matters
Process design engineers form the technical backbone of capital projects across the chemical, petrochemical, pharmaceutical, and energy sectors. According to the American Institute of Chemical Engineers (AIChE), design engineers working within EPC (engineering, procurement, and construction) firms develop the process flow diagrams, piping and instrumentation diagrams, heat and mass balances, and equipment specifications that define how a facility operates before a single pipe is welded. The BLS reports that architecture and engineering occupations had a median annual wage of $97,310 in May 2024, while chemical engineers specifically earned a median of $121,860 — reflecting the specialized knowledge these roles demand. The career path is well-defined and deeply technical. Entry-level process design engineers typically begin by assisting with equipment datasheets, running process simulations, and developing process flow diagrams under supervision. Mid-career engineers lead FEED (front-end engineering and design) packages, own P&ID development for entire process units, and coordinate with piping, instrumentation, and electrical disciplines. Senior process design engineers direct multi-unit design efforts valued at hundreds of millions of dollars, chair HAZOP studies, mentor junior staff, and serve as the technical authority on process guarantees. Demand is sustained by several structural forces. The energy transition is driving grassroots design work in hydrogen production, carbon capture, and battery materials. Pharmaceutical companies expanding biologics manufacturing capacity need process design engineers who understand cGMP facility layout. The reshoring of semiconductor and specialty chemical production in North America creates additional demand. According to the 2025 AIChE Salary Survey, median compensation for chemical engineers reached $160,000, with process design specialists in EPC firms and owner-operators commanding premium rates — particularly those holding a Professional Engineer (PE) license.
Entry-Level Process Design Engineer Resume
**When to use this template:** You have 0–2 years of experience, recently passed the Fundamentals of Engineering (FE) exam, and want to highlight internship contributions, academic projects, and early-career simulation work.
**JORDAN M. PATEL** Houston, TX 77056 | (832) 555-0194 | [email protected] | linkedin.com/in/jordanmpatel
Professional Summary
Process design engineer with 1.5 years of experience supporting FEED and detailed design for petrochemical projects at a Top 10 EPC firm. Developed heat and mass balances and equipment datasheets for a $340M ethylene glycol unit, contributing to a design package delivered 12 days ahead of the contractual milestone. Passed the Fundamentals of Engineering (FE) exam in chemical engineering with a score in the 91st percentile.
Education
**Bachelor of Science in Chemical Engineering** University of Texas at Austin — Austin, TX Graduated May 2023 | GPA: 3.72/4.00 - Senior Capstone: Designed a 50,000 bbl/day crude distillation unit using Aspen HYSYS; optimized reflux ratio to reduce reboiler duty by 8.3% - AIChE Student Chapter Vice President; organized plant tour program for 120 members
Professional Experience
**Process Design Engineer I** Wood Group | Houston, TX | July 2023 – Present - Developed 47 equipment datasheets (heat exchangers, columns, vessels, pumps) for a $340M ethylene glycol project, completing all deliverables 12 days ahead of the Level 3 schedule - Built steady-state Aspen HYSYS simulation models for 3 process units (reaction, separation, purification), validating design against licensor yields within ±1.5% deviation - Generated 22 process flow diagrams (PFDs) and assisted in development of 68 P&IDs using SmartPlant P&ID, resolving 134 inter-discipline comments during design reviews - Performed hydraulic calculations for 31 process lines ranging from 2" to 24" diameter, identifying 4 instances where pipe sizing needed upsizing to meet allowable velocity limits - Conducted relief valve sizing for 12 scenarios (fire case, blocked outlet, thermal expansion) per API 520/521 standards, documenting results in relief device summary sheets - Prepared operating and design conditions for 8 control valves using ISA methodology, coordinating with instrumentation discipline to finalize Cv requirements **Process Engineering Intern** Dow Chemical Company | Freeport, TX | May 2022 – August 2022 - Optimized distillation column reflux ratio using Aspen Plus simulation, reducing energy consumption by 6.2% ($180K/year savings) on a propylene oxide purification unit - Collected and analyzed 3 months of DCS operating data (4,200 data points) to identify heat exchanger fouling trends, recommending a cleaning schedule that restored 94% of design U-value - Created a process simulation template in Aspen HYSYS for the olefins team, adopted by 5 engineers and reducing model setup time by 40%
Technical Skills
**Process Simulation:** Aspen HYSYS, Aspen Plus, HTRI Xchanger Suite **Design Tools:** SmartPlant P&ID, AutoCAD, Microsoft Visio **Calculations:** Heat and mass balance, hydraulic analysis, relief valve sizing (API 520/521), equipment sizing **Standards:** ASME Section VIII, API 650/660/661, TEMA, ISA-75.01 **Programming:** Python (NumPy, Pandas), MATLAB, VBA for Excel automation **Software:** Microsoft Office Suite, SAP, Aconex document management
Certifications & Licenses
- Engineer in Training (EIT) — Texas Board of Professional Engineers, 2023
- OSHA 30-Hour General Industry Safety, 2023
Professional Affiliations
- American Institute of Chemical Engineers (AIChE), Member since 2020
- Society of Women Engineers (SWE), Member since 2021
Mid-Level Process Design Engineer Resume
**When to use this template:** You have 3–7 years of experience, lead P&ID development and FEED packages, and want to showcase capital project ownership and cross-discipline coordination.
**RACHEL A. DOMINGUEZ, P.E.** Baton Rouge, LA 70809 | (225) 555-0287 | [email protected] | linkedin.com/in/racheldominguez-pe
Professional Summary
Licensed process design engineer (PE) with 6 years of experience delivering FEED and detailed design for capital projects ranging from $85M to $620M in the petrochemical, refining, and LNG sectors. Led P&ID development and process simulation for a $620M LNG regasification terminal, achieving zero process-related change orders during construction. Certified Six Sigma Green Belt who implemented design standardization practices that reduced engineering hours by 18% across 3 concurrent projects.
Education
**Master of Science in Chemical Engineering** Louisiana State University — Baton Rouge, LA Graduated May 2019 | GPA: 3.85/4.00 | Thesis: "Optimization of Heat Exchanger Networks Using Pinch Analysis for Grassroots Petrochemical Facilities" **Bachelor of Science in Chemical Engineering** Louisiana State University — Baton Rouge, LA Graduated May 2017 | GPA: 3.68/4.00 | Magna Cum Laude
Professional Experience
**Senior Process Design Engineer** Bechtel Corporation | Houston, TX | March 2022 – Present - Led process design for a $620M LNG regasification terminal (160 MMSCFD send-out capacity), developing the complete process design basis, heat and mass balances, and equipment specifications for 4 process units - Owned P&ID development for 127 sheets across regasification, boil-off gas compression, metering, and utilities; managed resolution of 892 inter-discipline comments with zero critical items unresolved at IFC - Chaired 6 HAZOP study sessions (48 nodes) for the regasification unit, identifying 31 action items and ensuring all safeguards were incorporated into the design before Issued for Construction (IFC) milestone - Sized and specified 42 major equipment items (shell-and-tube exchangers, air-cooled exchangers, centrifugal compressors, pumps, vessels) using HTRI, Aspen HYSYS, and in-house sizing tools, achieving 100% first-pass vendor approval on 38 of 42 items - Developed the dynamic simulation model (Aspen HYSYS Dynamics) for the send-out system, validating compressor surge protection logic and ESD response times under 14 transient scenarios - Mentored 2 junior engineers on P&ID development standards and relief valve sizing, reducing review comment density on their deliverables by 35% over 6 months **Process Design Engineer II** Fluor Corporation | Sugar Land, TX | June 2019 – February 2022 - Executed detailed design for a $280M propane dehydrogenation (PDH) unit at a Gulf Coast petrochemical complex, developing simulation models, PFDs, and equipment datasheets for the reaction and separation sections - Generated heat and mass balances for 156 process streams with ±2% closure on all material and energy balances, enabling on-time delivery of the process design package - Performed flare system hydraulic analysis (14,200 ft of flare header) using Aspen Flare System Analyzer, identifying 2 header segments requiring upsizing from 36" to 42" to meet API 521 backpressure limits - Created cause-and-effect matrices for 8 emergency shutdown scenarios, coordinating with SIS and instrumentation teams to ensure SIL 2 compliance on 23 safety instrumented functions - Developed process datasheets for 18 control valves and 6 pressure safety valves, completing all valve specifications 3 weeks ahead of the procurement schedule - Reduced simulation model run time by 62% by restructuring the Aspen HYSYS flowsheet convergence sequence, saving an estimated 240 engineering hours across the project team over 14 months **Process Engineering Intern** BASF Corporation | Geismar, LA | May 2018 – August 2018 - Analyzed 18 months of production data for a methylene diphenyl diisocyanate (MDI) unit to identify yield loss sources, recommending 3 operational changes that improved yield by 1.8% ($420K/year) - Developed a Python-based heat exchanger monitoring dashboard that tracked fouling factors in real time for 24 exchangers, adopted by the site reliability engineering team
Technical Skills
**Process Simulation:** Aspen HYSYS, Aspen Plus, Aspen Flare System Analyzer, HTRI Xchanger Suite, ProMax, Aspen HYSYS Dynamics **Design Tools:** SmartPlant P&ID, AutoCAD P&ID, AVEVA E3D, Navisworks **Calculations:** Heat and mass balance, hydraulic analysis, relief valve sizing (API 520/521), flare system analysis, control valve sizing, dynamic simulation **Standards:** ASME B31.3, ASME Section VIII, API 520/521/526/650/660/661, TEMA, NFPA 59A, 49 CFR 193 **Methodologies:** HAZOP, LOPA, SIL verification, bow-tie analysis, what-if analysis **Programming:** Python (Pandas, SciPy, Matplotlib), VBA, MATLAB **Project Tools:** Primavera P6, SAP, Aconex, SharePoint, Bluebeam Revu
Certifications & Licenses
- Professional Engineer (PE) — Louisiana Board of Professional Engineers, License #42871, 2023
- Certified Six Sigma Green Belt (CSSGB) — ASQ, 2022
- HAZOP Study Leader — IChemE-accredited training, 2021
- OSHA 30-Hour General Industry Safety, 2019
Professional Affiliations
- American Institute of Chemical Engineers (AIChE), Member since 2016
- Society of Petroleum Engineers (SPE), Member since 2019
Senior-Level Process Design Engineer Resume
**When to use this template:** You have 8+ years of experience, serve as lead process engineer or process engineering manager on major capital projects, and need to highlight FEED leadership, team management, and multi-project oversight.
**DAVID K. JOHANSSON, P.E., PMP** Katy, TX 77494 | (281) 555-0463 | [email protected] | linkedin.com/in/davidkjohansson
Professional Summary
Senior process design engineer and project technical lead with 14 years of experience directing FEED and detailed design for capital projects totaling over $2.8B across the refining, petrochemical, LNG, and hydrogen sectors. Managed process engineering teams of up to 22 engineers on a $1.1B grassroots hydrogen plant, delivering the FEED package on budget with zero safety-critical design deficiencies identified during independent design review. Licensed PE in Texas and Louisiana with PMP certification and HAZOP leadership accreditation.
Education
**Master of Science in Chemical Engineering** Rice University — Houston, TX Graduated May 2013 | Concentration: Process Systems Engineering **Bachelor of Science in Chemical Engineering** Texas A&M University — College Station, TX Graduated May 2011 | GPA: 3.81/4.00 | Summa Cum Laude | University Honors
Professional Experience
**Lead Process Design Engineer / Process Engineering Manager** Technip Energies | Houston, TX | January 2020 – Present - Served as Lead Process Engineer on a $1.1B blue hydrogen production facility (200,000 Nm³/h capacity with 95% carbon capture), managing a process engineering team of 22 engineers across FEED and detailed design phases over 28 months - Directed development of 247 P&IDs, 86 PFDs, and the complete process design basis document for 7 process units (SMR, shift conversion, CO₂ removal, methanation, PSA, carbon capture, utilities), delivering the FEED package $1.2M under the engineering budget - Led 14 HAZOP study sessions (112 nodes) and 4 LOPA workshops, identifying 87 action items and achieving zero unresolved critical-risk findings before IFC; received commendation from the owner's independent safety reviewer - Developed process guarantees for hydrogen purity (99.97%), carbon capture rate (95.2%), and specific energy consumption (9.8 GJ/ton H₂), all validated through rigorous simulation and confirmed during commissioning within ±0.5% of design targets - Established a process engineering competency development program for junior and mid-level engineers, including standardized training modules on relief valve sizing, HAZOP methodology, and dynamic simulation; program adopted across 3 regional offices - Coordinated with 6 technology licensors (SMR, amine, PSA, membranes) to integrate proprietary process designs into the overall plant configuration, resolving 43 interface issues during design integration workshops **Senior Process Design Engineer** KBR, Inc. | Houston, TX | April 2016 – December 2019 - Led process engineering for a $480M refinery crude and vacuum unit revamp (capacity increase from 180,000 to 225,000 bbl/day), completing the FEED package in 9 months with a design accuracy of ±10% on CAPEX estimate - Developed steady-state and dynamic simulation models for the crude unit, vacuum unit, and associated heat recovery systems using Aspen HYSYS; dynamic model validated compressor anti-surge logic and emergency depressurization sequences for 8 scenarios - Owned process design for a $165M delayed coker unit expansion, sizing 28 major equipment items and developing 74 P&IDs achieved zero process-related punch list items during mechanical completion - Chaired 9 HAZOP sessions (67 nodes) across 2 concurrent refinery projects, managing a multi-discipline team of 14 specialists and closing all action items within 30 days of each study - Reduced overall engineering hours by 14% ($380K savings) on the crude unit revamp by implementing standardized P&ID development workflows and reusable simulation templates - Mentored 6 process engineers (EIT through mid-level), with 3 subsequently passing the PE exam and 2 promoted to senior roles **Process Design Engineer** WorleyParsons (now Worley) | Houston, TX | June 2013 – March 2016 - Executed detailed design for a $220M ethanol-to-ethylene dehydration plant, developing all PFDs, H&MBs, and equipment datasheets for the dehydration reactor section, quench system, and ethylene purification train - Built the Aspen Plus simulation model for the complete ethanol dehydration process, optimizing reactor inlet temperature and steam-to-ethanol ratio to achieve 99.5% ethanol conversion at 8% lower specific energy consumption than the licensor's base case - Performed line sizing calculations for 142 process and utility lines using in-house hydraulic tools, identifying 7 lines requiring resizing and 3 requiring metallurgy upgrades due to corrosion allowance requirements - Developed the control philosophy for 6 major process units in collaboration with the instrumentation team, specifying 34 control loops, 12 cascade configurations, and 8 override schemes - Prepared 15 operating procedure outlines for the commissioning team, covering startup, shutdown, normal operation, and emergency scenarios for the reactor and purification sections **Junior Process Engineer** Shell Global Solutions | Houston, TX | August 2011 – May 2013 - Supported process optimization studies for 3 operating refineries, analyzing DCS data and developing recommendations that collectively delivered $2.1M/year in energy savings - Modeled crude distillation column performance in Aspen HYSYS to evaluate the impact of processing 4 alternative crude blends, enabling the refinery planning team to capture a $0.85/bbl margin improvement on a 120,000 bbl/day unit - Assisted in HAZOP revalidation studies for 2 process units (hydrotreater, hydrogen plant), documenting findings for 34 nodes and tracking resolution of 18 action items
Technical Skills
**Process Simulation:** Aspen HYSYS, Aspen Plus, Aspen HYSYS Dynamics, Aspen Flare System Analyzer, HTRI Xchanger Suite, ProMax, UniSim Design, PRO/II **Design Tools:** SmartPlant P&ID, AutoCAD P&ID, AVEVA E3D, COMOS, Navisworks **Calculations:** Heat and mass balance, hydraulic analysis, relief valve sizing (API 520/521), flare system analysis (API 521), control valve sizing, dynamic simulation, pinch analysis, fired heater design **Standards:** ASME B31.3, ASME Section VIII, API 520/521/526/560/650/660/661, TEMA, NFPA 30/59A, 49 CFR 193, IEC 61511 **Methodologies:** HAZOP, LOPA, SIL classification/verification, bow-tie analysis, QRA, ALARP demonstration **Programming:** Python (Pandas, SciPy, Matplotlib, automation scripts), VBA, MATLAB **Project Management:** Primavera P6, Microsoft Project, Earned Value Management, gate-stage project delivery **Document Management:** Aconex, EDMS, SharePoint, Bluebeam Revu
Certifications & Licenses
- Professional Engineer (PE) — Texas Board of Professional Engineers, License #128934, 2017
- Professional Engineer (PE) — Louisiana Board of Professional Engineers, License #41205, 2018
- Project Management Professional (PMP) — Project Management Institute, 2020
- Certified Six Sigma Black Belt (CSSBB) — ASQ, 2019
- HAZOP Study Leader — IChemE-accredited training, 2016
- API 510 Certified Pressure Vessel Inspector, 2021
Professional Affiliations
- American Institute of Chemical Engineers (AIChE), Senior Member since 2012
- American Society of Mechanical Engineers (ASME), Member since 2014
- Society of Petroleum Engineers (SPE), Member since 2013
Select Publications & Presentations
- "Integrating Carbon Capture into Blue Hydrogen FEED: Lessons from a 200,000 Nm³/h Facility," AIChE Spring Meeting, Houston, TX, 2024
- "Dynamic Simulation as a Design Verification Tool for LNG Regasification Terminals," Gas Processors Association Annual Convention, 2021
- Co-author, "Optimizing Heat Exchanger Network Design Using Pinch Analysis: A Grassroots Petrochemical Case Study," *Chemical Engineering Research and Design*, Vol. 142, 2019
Key Skills & ATS Keywords
Applicant tracking systems used by EPC firms (Bechtel, Fluor, KBR, Technip, Worley, Wood) and owner-operators (Shell, ExxonMobil, Dow, BASF) parse resumes for specific technical terms. Include these keywords naturally throughout your resume to maximize ATS compatibility.
Process Engineering Core
- Process flow diagram (PFD) development
- Piping and instrumentation diagram (P&ID)
- Heat and mass balance (H&MB)
- Process design basis
- Equipment sizing and specification
- Hydraulic analysis and line sizing
- Relief valve sizing (API 520/521)
- Flare system design and analysis
- Control valve sizing (ISA-75.01)
- Control philosophy development
- Cause-and-effect matrix
- Operating procedure development
Process Safety
- HAZOP study (leader/participant)
- Layer of protection analysis (LOPA)
- Safety integrity level (SIL) classification
- Bow-tie analysis
- Quantitative risk assessment (QRA)
- Management of change (MOC)
- Process hazard analysis (PHA)
Software & Simulation
- Aspen HYSYS / Aspen Plus
- Aspen HYSYS Dynamics
- HTRI Xchanger Suite
- Aspen Flare System Analyzer
- SmartPlant P&ID / AutoCAD P&ID
- ProMax / UniSim Design / PRO/II
- AVEVA E3D / COMOS
- Python / MATLAB / VBA
Project Phases
- Front-end engineering and design (FEED)
- Detailed design / Issued for Construction (IFC)
- Conceptual design / feasibility study
- Commissioning and startup support
- Brownfield revamp / debottlenecking
Professional Summary Examples
Example 1: Mid-Career EPC Engineer
"Process design engineer with 5 years of experience executing FEED and detailed design for petrochemical and refining capital projects at Fluor and Wood Group. Led P&ID development for a $420M propylene splitter installation (98 P&ID sheets), coordinated HAZOP studies for 52 nodes, and sized 36 major equipment items with 97% first-pass vendor approval. Holds PE license in Texas and Six Sigma Green Belt certification."
Example 2: Senior Engineer Transitioning to Owner-Operator
"Senior process design engineer and HAZOP study leader with 11 years of EPC experience (Bechtel, KBR) seeking to apply deep capital project expertise in an owner-operator environment. Directed process engineering teams of up to 18 engineers on projects totaling $1.6B across LNG, hydrogen, and refining sectors. Delivered 3 consecutive FEED packages on schedule with zero safety-critical design deficiencies. PE licensed in Texas and Louisiana; PMP certified."
Example 3: Entry-Level with Strong Internship Experience
"Chemical engineering graduate (University of Houston, 3.74 GPA) and Engineer in Training (EIT) with internship experience at BASF Geismar and Phillips 66 Sweeny Refinery. Developed Aspen HYSYS simulation models for distillation and reaction systems, performed heat exchanger performance analysis using HTRI, and contributed to P&ID development for a $95M unit expansion. Seeking a process design engineer role at an EPC firm to apply simulation and design skills on large-scale capital projects."
Common Mistakes to Avoid
1. Listing Software Without Showing Application
Writing "Proficient in Aspen HYSYS" tells a hiring manager nothing. Instead, specify what you modeled: "Built steady-state Aspen HYSYS model for a 50,000 bbl/day crude distillation unit, optimizing stripping steam rates to reduce energy consumption by 7.4%." Every software mention should be tied to a deliverable and a measurable outcome.
2. Omitting Project Scale and CAPEX Values
Process design engineering is fundamentally a capital projects discipline. A resume that says "Led process design for a refinery project" leaves the reader guessing. Always include the project value ("$480M crude unit revamp"), capacity ("225,000 bbl/day"), and your specific scope ("74 P&IDs, 28 equipment items"). These numbers immediately signal your experience level to recruiters and hiring managers.
3. Using Generic Action Verbs Instead of Engineering-Specific Language
Phrases like "assisted with various engineering tasks" or "helped the team complete deliverables" obscure your actual contribution. Use precise engineering verbs: "sized," "specified," "modeled," "validated," "developed," "optimized," "chaired" (for HAZOP), "resolved" (for inter-discipline comments). Each bullet should make clear exactly what you designed, calculated, or delivered.
4. Ignoring Process Safety Credentials
HAZOP leadership, LOPA experience, and SIL verification are differentiators that many candidates undervalue. If you have chaired or participated in HAZOP studies, state the number of sessions, nodes reviewed, and action items identified. Hiring managers at EPC firms and owner-operators specifically seek engineers who can lead safety reviews — it is a skill that directly correlates with seniority and compensation.
5. Failing to Distinguish FEED from Detailed Design Experience
These are different phases requiring different skills. A resume that lumps all project work together misses an opportunity to demonstrate career progression. FEED work involves design basis development, technology selection, and ±25% cost estimates. Detailed design involves IFC-quality deliverables, vendor coordination, and construction support. Clearly label which phase each project involved.
6. Neglecting to Quantify Design Accuracy and Schedule Performance
Saying you "completed the design package" is insufficient. Did you deliver ahead of the Level 3 schedule? Was the CAPEX estimate within ±10% accuracy? Did you achieve zero process-related change orders during construction? These metrics demonstrate engineering rigor and directly address what project managers and chief engineers care about.
7. Burying Licensure and Certifications Below the Fold
Your PE license, EIT status, PMP, and Six Sigma certifications should be visible within the first 10 seconds of a recruiter scanning your resume. Many EPC firms filter candidates by PE status. Place these credentials immediately after your name or in a dedicated section near the top of the document.
ATS Optimization Tips
1. Match the Exact Job Posting Terminology
If the posting says "P&ID development," use that exact phrase rather than "piping and instrumentation diagram creation." If it says "Aspen HYSYS," do not abbreviate to "HYSYS" alone. ATS systems perform keyword matching, and variations may not register as matches. Include both the acronym and the spelled-out form where space permits.
2. Use a Clean, Single-Column Format
Multi-column layouts, tables, text boxes, and graphics confuse ATS parsers. Use a single-column format with clear section headings (Professional Summary, Experience, Education, Skills, Certifications). Avoid headers and footers for critical information — many ATS systems skip those sections entirely.
3. Include Standard Section Headings
Use headings that ATS systems recognize: "Professional Experience" or "Work Experience" (not "Career Journey"), "Education" (not "Academic Background"), "Technical Skills" (not "Toolkit"), "Certifications" (not "Credentials & Accreditations"). Standardized headings ensure proper field mapping.
4. Spell Out Acronyms on First Use
Write "front-end engineering and design (FEED)" the first time, then use "FEED" thereafter. The same applies to "piping and instrumentation diagram (P&ID)," "heat and mass balance (H&MB)," and "hazard and operability study (HAZOP)." This ensures the ATS captures the match regardless of whether the recruiter searches for the acronym or the full phrase.
5. Quantify Every Experience Bullet
ATS systems do not evaluate quality, but hiring managers who review ATS-passed resumes do. Every bullet should contain at least one number: project value ($M), equipment count, P&ID count, improvement percentage, schedule days, team size, or node count. Numbers break up text visually and provide the specificity that distinguishes a strong resume from a generic one.
6. Include a Dedicated Technical Skills Section
List simulation software (Aspen HYSYS, Aspen Plus, HTRI), design tools (SmartPlant P&ID, AutoCAD P&ID), standards (API 520/521, ASME B31.3), and methodologies (HAZOP, LOPA, SIL) in a separate skills section. This concentrated keyword section ensures ATS systems capture your technical qualifications even if they struggle to parse context from experience bullets.
7. Save as .docx Unless the Posting Specifies PDF
Most modern ATS systems handle both formats, but .docx remains the safest choice for parsing accuracy. If you submit a PDF, ensure it is text-based (not a scanned image) so the ATS can extract content. Avoid creative file naming — use "Firstname_Lastname_Process_Design_Engineer.docx" for clarity.
Frequently Asked Questions
Do I need a PE license to work as a process design engineer?
A PE license is not strictly required for most process design engineer positions at EPC firms, as engineers typically work under the supervision of a licensed PE who stamps the final deliverables. However, holding a PE license significantly expands your career options and earning potential. Many senior and lead process engineer positions at firms like Bechtel, Fluor, KBR, and Technip Energies list the PE as required or strongly preferred. Owner-operators (Shell, ExxonMobil, Chevron, Dow) frequently require a PE for roles involving design authority or stamp responsibility. According to the National Society of Professional Engineers (NSPE), PE-licensed engineers earn 10–15% more than their non-licensed peers at comparable experience levels. The path requires passing the Fundamentals of Engineering (FE) exam, accumulating 4 years of progressive experience under a licensed PE, and passing the Principles and Practice (PE) exam in chemical engineering.
What simulation software should I highlight on my resume?
Aspen HYSYS and Aspen Plus are the most widely used process simulators in the EPC and petrochemical industries and should appear on virtually every process design engineer resume. Beyond these, HTRI Xchanger Suite (for heat exchanger thermal design), Aspen Flare System Analyzer (for flare and relief system analysis), and SmartPlant P&ID or AutoCAD P&ID (for diagram development) are standard tools that hiring managers expect. If you have experience with ProMax (gas processing), UniSim Design (Honeywell environments), or Aspen HYSYS Dynamics (dynamic simulation and control studies), include those as well — dynamic simulation capability is increasingly valued for complex projects involving compressor control, ESD validation, and operability studies. List the specific version or modules you have used if the posting requests that level of detail.
How do I show HAZOP experience on my resume if I was only a participant, not a leader?
HAZOP participation is still valuable and belongs on your resume. Specify your role clearly: "Participated in 4 HAZOP study sessions (32 nodes) for a $280M PDH unit, providing process design input on 18 safeguard recommendations." If you acted as the process engineering representative (which is the default role for a process design engineer in a HAZOP), state that: "Served as process engineering representative for HAZOP studies covering the reaction and separation sections, preparing process descriptions, P&IDs, and operating parameters for 45 nodes." As you gain experience, pursue IChemE or equivalent HAZOP leader training to transition from participant to chair — this is a recognized career milestone in process design engineering.
Should I include academic projects on my resume if I have professional experience?
If you have fewer than 3 years of professional experience, yes — a strong senior capstone project demonstrates simulation skills, design thinking, and technical communication before you have a deep portfolio of professional work. Focus on projects that involved process simulation (Aspen HYSYS or Aspen Plus), equipment design, or process optimization with quantifiable results. Once you have 3+ years of professional experience, academic projects should generally be removed to make space for professional accomplishments, unless the project resulted in a publication or is directly relevant to the target role.
What is the difference between a process engineer and a process design engineer?
The terms overlap substantially, but "process design engineer" specifically refers to engineers who work in the design phase of capital projects — creating PFDs, P&IDs, heat and mass balances, equipment specifications, and process simulation models. A "process engineer" is a broader title that may also encompass operations support, troubleshooting, process optimization in a manufacturing environment, and technical services. In EPC firms, the distinction is clear: process design engineers work on project teams developing new facilities or major modifications. In owner-operator environments, the same engineer might do both design and operations support. On your resume, use the title that matches the job posting. If the posting says "Process Design Engineer," use that title. If it says "Process Engineer" with design-focused duties, emphasize your design deliverables and capital project experience in your bullets.
Citations & Sources
- U.S. Bureau of Labor Statistics. "Chemical Engineers: Occupational Outlook Handbook." BLS.gov. Accessed February 2025. https://www.bls.gov/ooh/architecture-and-engineering/chemical-engineers.htm
- U.S. Bureau of Labor Statistics. "Occupational Employment and Wage Statistics: 17-2199 Engineers, All Other." BLS.gov, May 2023 data. https://www.bls.gov/oes/2023/may/oes172199.htm
- U.S. Bureau of Labor Statistics. "Architecture and Engineering Occupations: Occupational Outlook Handbook." BLS.gov. Accessed February 2025. https://www.bls.gov/ooh/architecture-and-engineering/
- American Institute of Chemical Engineers. "Career Options for ChEs: Process and Design Engineering." AIChE Chenected, August 2022. https://chenected.aiche.org/2022/08/career-options-ches-process-and-design-engineering
- American Institute of Chemical Engineers. "The 2025 AIChE Salary Survey Results Are In!" AIChE Chenected, June 2025. https://chenected.aiche.org/2025/06/2025-aiche-salary-survey-results-are
- American Institute of Chemical Engineers. "Process Design & Development." AIChE.org. https://www.aiche.org/topics/chemical-engineering-practice/process-design-development
- Salary.com. "Process Design Engineer Salary." Salary.com, 2025. https://www.salary.com/research/salary/recruiting/process-design-engineer-salary
- Zippia. "4 Best Process Design Engineer Certifications in 2024." Zippia.com. https://www.zippia.com/process-design-engineer-jobs/certifications/
- PayScale. "Process Engineer Salary in 2025." PayScale.com. https://www.payscale.com/research/US/Job=Process_Engineer/Salary
- American Society of Mechanical Engineers. "Demand and Salaries Grow for Mechanical Engineers." ASME.org, 2025. https://www.asme.org/topics-resources/content/demand-and-salaries-grow-for-mechanical-engineers