The Senior Thermodynamics Engineer – Boiler Heat Transfer leads the development, analysis, and optimization of thermal systems in industrial and utility-scale boiler operations. This role is responsible for directing thermal design initiatives, improving energy efficiency, troubleshooting complex heat transfer problems, and guiding engineering teams through advanced modeling and performance testing. The engineer ensures boiler systems meet operational, regulatory, and energy targets through robust thermal design and analysis.
Lead complex thermal performance evaluations for boiler components including economizers, superheaters, reheaters, and furnace zones.
Develop and validate advanced thermal models using software such as MATLAB, EES, Aspen Plus, or CFD tools (e.g., ANSYS Fluent).
Drive heat balance studies, efficiency audits, and heat loss assessments to recommend performance enhancements.
Supervise and mentor junior engineers on thermodynamic analysis, system simulation, and field diagnostics.
Lead root cause investigations into high-temperature failures, fouling, thermal fatigue, or material degradation in heat transfer zones.
Develop and review design specifications, retrofit proposals, and performance testing protocols aligned with ASME PTC 4, Section I, and API standards.
Collaborate with plant operations and maintenance teams to resolve persistent thermal issues, optimize burner configurations, and improve load-following behavior.
Interface with OEMs and engineering consultants during new boiler design, upgrades, or expansions.
Support capital projects involving energy recovery systems, advanced heat exchanger technologies, and low-NOx burner integration.
Thermal Design and Optimization
Lead thermal analysis and design improvements that maximize boiler heat transfer efficiency and reduce energy losses.
Advanced Heat Transfer Modeling
Apply computational and analytical methods for simulating radiant, convective, and conductive heat flow in complex boiler geometries.
Efficiency Enhancement and Energy Reduction
Implement strategies to reduce stack losses, excess air, radiation losses, and optimize air preheater and feedwater systems.
Combustion-Thermal Integration
Integrate combustion analysis with heat transfer modeling to improve overall thermal efficiency and emission control.
Boiler Reliability and Lifecycle Analysis
Contribute to long-term boiler health assessments, life extension analysis, and thermal stress evaluations for pressure components.
Bachelor’s or Master’s degree in Mechanical Engineering, Thermal Engineering, or related field.
8+ years of relevant experience in boiler heat transfer design, thermal systems engineering, or energy efficiency projects.
Advanced knowledge of thermodynamics, fluid dynamics, and heat transfer mechanisms.
Proficiency with modeling and simulation software (e.g., MATLAB, EES, ANSYS, Aspen Plus).
Strong background in boiler codes, performance testing standards, and materials engineering.
Proven ability to lead cross-functional engineering teams and manage multiple technical workstreams.
Excellent technical writing, presentation, and communication skills.