Process Modeling Engineer

Job Description

Process Modeling — Level 2 Automation

Helion | Apple Grove, WV

Onsite | Monday–Friday, 7 AM–4 PM

Want to use your engineering knowledge to write software that controls a real manufacturing process?

Helion is seeking an engineer who can translate physics, mathematics, and process data into models that determine how a manufacturing facility operates. You’ll support the commissioning and optimization of a new steel manufacturing facility.

Mechanical engineers who moved into software development—and want to return to solving physical engineering problems—are encouraged to apply.

What you’ll own

Develop, maintain, and improve physics-based process models that calculate operating setups and targets. Approximately 80% of the focus is understanding and applying the physics , with software and databases serving as the tools to implement and support those models.

For example, a casting model uses material properties, temperature targets, and operating conditions to calculate cooling flows needed to produce the desired metal properties.

Your first day

You’ll begin learning your assigned process area, reviewing the existing model and code with the team, and tracing how information moves through the system:

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• Which sensor measurements feed the model.
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• How that information is stored and retrieved in SQL or Oracle.
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• What physical relationships and assumptions drive the calculations.
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• How calculated targets reach Level 1 controls and influence equipment operation.
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Come prepared to discuss engineering fundamentals, explain your approach to unfamiliar code, and ask questions about how the physical process works. You’ll build plant-specific knowledge alongside experienced engineers and operators.

Typical day-to-day

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• Review process trends and compare model predictions with actual operating results.
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• Apply thermodynamics, heat transfer, fluid mechanics, calculus, and differential equations to investigate process behavior.
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• Develop and troubleshoot C# code supporting process models and operating setups.
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• Use SQL or Oracle to retrieve sensor histories, investigate abnormalities, and validate model inputs.
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• Determine whether a performance issue comes from sensor data, model assumptions, software, or changing process conditions.
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• Work with metallurgists, operators, Level 1 controls engineers, and equipment suppliers to refine process targets.
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• Test and document model changes, then evaluate their effect on quality, consistency, and throughput.
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• Support commissioning and continued tuning as equipment and production conditions evolve.
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What we’re looking for

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• A degree in mechanical, chemical, electrical, aerospace engineering, engineering physics, or a related technical discipline.
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• Strong understanding of applied physics, calculus, differential equations, and numerical methods.
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• Experience translating engineering calculations or mathematical models into software.
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• C# programming experience and familiarity with SQL or Oracle databases.
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• Ability to explain why a model works, recognize its limitations, and validate it against measured results.
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• Interest in working onsite with the equipment and people affected by your software.
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Relevant backgrounds include process modeling, scientific software development, thermal/fluid simulation, computational engineering, and engineering combined with software development .

Interested? Message me with your resume and a brief example of a physical process you’ve modeled or an engineering application you’ve developed.