How to become A Chemical Operator

• Chemical Process Operator
• Chemical Plant Operator
• Chemical Plant & Systems Operator
• Process Control Operator
• Process Technician

A Chemical Operator would typically need to:

• Run production systems in chemical plants; oversee industrial equipment, chemical processes, process technologies, and plant personnel 
• Operate and control plant equipment and perform chemical operations following standard operating procedures (SOPs),  company policies & procedures, and safety rules & protocols 
• Be trained in using personnel protection equipment (PPE) and use it as stipulated
• Follow GMPs (good manufacturing practices) and maintain a clean work centre, particularly while manufacturing pharmaceuticals, food and beverages
• Train new employees in GMPs and department SOPs so that they comply with quality standards, thereby minimising risks before final product testing
• Safely handle fixed and rotating process equipment which performs tasks such as maintaining chemical flows or controlling chemical reactions
• Manage semi-automated and automated systems that process chemical substances into industrial and consumer products, such as acids, emulsifiers, synthetic resins, detergents, salts, and bleaching agents
• Carefully handle, transport, store and use chemicals and reagents
• Inspect and conduct routine maintenance on equipment; troubleshoot and fix malfunctions that may slow down or interrupt production
• Repair or replace defective parts per the budget and deadlines to minimise downtime and optimise safety, efficiency and productivity
• Transport raw materials to processing facilities safely; load and unload rail cars, tank trucks, holding vessels and ships using equipment such as forklifts, conveyors, and hoists
• Transfer material to holding vessels for filling drums; monitor vessel temperatures, flow rates and levels
• Assemble, dispense and monitor raw materials as inputs to produce intermediate materials that feed into manufacturing other products
• Put defined quantities of solid materials into vessels or tanks for heating or blending
• Operate valves to feed liquids and gases into the system or automate the feed by setting panel controls in a specified sequence
• Observe and control mixing processes and chemical reactions taking place during production to maintain consistent product quality and production rates 
• Monitor and manage batch process conditions and variables, incuding the temperature, clarity and volume of batches under processing, using control systems; document values per SOPs
• Closely monitor recording devices, gauges, recorders, dials, flowmeters, panel lights, and other indicators to ensure that machines and processes run efficiently
• Turn valves or use the control panel to regulate system, equipment and process parameters, such as temperature, pressure and vacuum levels
• Listen to distress signals and respond to notifications from the control lab and staff by making specified adjustments to restore operational parameters
• Monitor lab hydration levels and impact on product dryness
• Understand and abide by quality regulations; inspect and evaluate product quality
• Collect lab samples of materials and products and run chemical tests on them, using standard test equipment, materials and procedures to check if they meet specifications
• Ensure and enhance product quality or service by removing existing product defects or adding improved features to generate customer satisfaction
• Document plant processes and maintenance tasks; enter readings on logs and production data on master batch records
• Conduct inventory management; inform supervisors of materials that must be introduced or reordered
• Package and store products in warehouses after accurately weighing them to match packaging documentation
• Use equipment to clean contaminated areas and remove hazardous materials
• Clean reactors, filters and other technical equipment and devices; change cartridges on various filters
• Manage emergencies and planned outages by regulating or shutting down equipment following the limits set by SOPs and maintaining shifts and
• schedules in coordination with technical workers and supervisors 
• Train civilian bodies to respond to emergencies using decontamination and mitigation procedures
• Contribute technical inputs to the company’s chemical research, process development and strategic initiatives to boost quality, safety and productivity; suggest feasible improvements to plant SOPs and equipment
• Keep current and work with the latest technology and materials

Operators of chemical plants typically work in industrial plants and facilities. They may work both indoors and outdoors and are exposed to fumes, dust, hazardous substances, extremes of temperature, and loud noise. Indoor spaces may be cramped.

You must wear PPE (personal protective equipment), including safety glasses, goggles, face shields, gloves, lab coats, aprons, earplugs, and respirators, to protect yourself from injuries, infections, and coming into contact with hazardous contaminants and chemicals.

Most Chemical Operators work full time on a rotational shift basis, which means that, in addition to daytime work, you may need to take turns working late evening, night and weekend shifts to keep plants running around the clock. Occasional overtime work may be necessary to meet project deadlines or deal with emergencies.

Finding a new job might seem challenging. Chemical Operators can boost their job search by asking their network for referrals, contacting processing and manufacturing companies directly, using job search platforms, going to job fairs, leveraging social media, and inquiring at staffing agencies.

Chemical Operators are usually hired by:

• Paint Manufacturers
• Pesticide Manufacturers
• Refined Oil Producers
• Manufacturers of Synthetic Plastics
• Manufacturers of Explosives
• Manufacturers of Industrial Chemical Products
• Food & Beverage Manufacturers
• Petrochemical Firms
• Biotech Companies

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• Working safely with hazardous materials and industrial equipment to avoid injuries and diseases; heeding warning signals; avoiding equipment failures, insufficient safety checks and operator errors
• Physically strenuous work that requires standing for long periods, heavy lifting, and correctly handling materials, tools and machinery, whether installing, positioning, moving or manipulating them
• The impact on health from working on rotating shifts, which include night shifts
• Ensuring the transfer of knowledge between experienced operators and new entrants 
• Acquiring digital literacy to supplement scientific understanding and skills; using mobile connected worker technologies, such as configurable digital work instructions to boost operational safety and efficiency
• The declining need for operators due to advances in technology which make equipment computerised and more efficient 
• Supply chains of raw materials worldwide prone to the disruptive impact of geopolitical issues, sea lane blockages and pandemics
• Contributing to fighting climate change and minimising greenhouse gas emissions by using renewable resources and sustainable processes

Any academic program undertaken by a potential Chemical Operator typically requires a period of supervised experience, such as an internship. Some employers may require high school graduates to have also completed at least six months of full-time post-secondary education to count as experience.

Aspiring Chemical Operators with some experience in the manufacturing industry, preferably with chemical processes, have a competitive edge in the job market. They must also demonstrate skills and experience in troubleshooting, minor repairs and preventive maintenance of equipment.

Experience as a store manager or in a role that fosters your communication, training, problem-solving, and leadership skills may be beneficial as you may need to train your team, adapt to your environment, and source quick and reliable solutions. 

Read about the profession and interview or job shadow experts working in chemical operations to prove your commitment to course providers and prospective employers.

Aspiring Chemical Operators must typically have at least a high school diploma or equivalent from an accredited institution. Some employers may require you to have completed a career and technical education (CTE) program before graduating from high school. You may also pursue a certificate, diploma, associate or bachelor’s degree program in chemical technology, chemical engineering, chemistry or a related field to foster career progression.

Computer skills may also help increase your chances of getting hired as a Chemical Operator, and working knowledge of Microsoft can come in handy.

High school chemistry, physics, biology, mathematics, and IT courses are helpful for aspiring Chemical Operators.

Certification helps Chemical Operators learn about potential industrial accidents and how to avoid them using appropriate mitigation techniques when working in chemical facilities and process technology industries. It helps them ensure that plants safely produce, refine and hand over chemicals in all states of matter. 

When acquired from an objective and reputed organisation, certification can also help you stand out in a competitive job market, carry a significant salary premium of up to 18 per cent, increase your chances of advancement and allow you to become an independent consultant. Successful certification programs protect public welfare by incorporating a Code of Ethics.

It is advisable to acquire operator or production technician certification demonstrating your competence in the technical skills needed to control systems and devices related to analytical processing, temperatures, pressures, and product transfer. You will typically earn your credentials based on an examination that tests your knowledge, experience, and training in safely operating equipment such as pumps, valves, and vessels.

Chemical Operators will do well to obtain further certification in areas such as chemical processes, occupational health & safety, machinery safety, equipment-specific safety, forklift safety, inspection, fire suppression, fire protection & safety, incident safety, and risk management practices. 

Consider acquiring GMP (good manufacturing practices) certification, which ensures consistent adherence to quality standards in all production aspects, including the starting materials, equipment and premises, and staff training in personal hygiene.

Some employers or locations may require Chemical Operators to have a licence to work with specific chemicals. Typically, licensure requires an application, processing fees, an examination, and relevant education and experience.

Performance, experience, and the acquisition of professional qualifications drive career progression. Employees with consistently high levels of performance may be eligible for promotion every two to three years.

With experience and having built the skill set needed, you could head to quality control, lab work, maintenance or shift management. Further academic qualifications, certification and specialised experience could help you become a Process Technician and advance to supervisory roles. You could specialise in particular equipment, processes or chemical substances used in chemical processing. 

Acquiring a degree in chemical engineering helps facilitate progression to technical and managerial roles, such as Process Engineer, Industrial Engineer, Safety Engineer, Environmental Engineer, Production Manager, Operations Manager, Maintenance Manager, and, eventually, Plant Manager. However, extensive experience and on-the-job training across the plant may substitute for higher academic qualifications and help you advance your career.

Given the similarity of duties, Chemical Operators working in chemical plants could become Petroleum Pump System Operators, Refinery Operators and Gaugers employed in petroleum refining plants to monitor gauges and indicators, operate technical equipment and handle emergencies. You could also diversify to become Gas Compressors and Gas Pumping Station Operators who operate compressors for gas transmission, compression or recovery. They also deal with equipment to process and store butane, hydrogen and natural gas, and other hazardous substances.

Candidates with chemical processing skills, experience in dealing with automated systems and environmentally-friendly processes and chemical substances, and higher academic qualifications have the best job prospects.

Continuing professional development (CPD) will help an active Chemical Operator build personal skills and proficiency through work-based learning, a professional activity, formal education, or self-directed learning. It allows you to continually upskill, regardless of your age, job, or level of knowledge.

Training on the job will teach you about specific production processes, equipment, materials, products, and quality control. It is critical to learn and stay updated with safety, health, hygiene & emergency protocols. Your employers will ensure that you develop a thorough knowledge of chemical substances used as input materials, how various chemicals interact, how to safely manufacture, store, handle, transport, and dispose of them, and how to recognise danger signs and respond to them. 

Work towards acquiring relevant certifications to boost career progression. CPD courses may be necessary to renew your certification periodically.

You can finetune or update your skills in operating technical tools and heavy equipment while developing a deeper understanding of their design, maintenance and repairs. Developing skills in troubleshooting, process control, maintenance, and safety boosts your marketability across industries. 

IT courses will help you build the skills you need to program and maintain automated equipment and systems that are being increasingly used in chemical plant operations, as they enhance production efficiency and quality control while reducing costs.

Another area of development for Chemical Operators is environmental sustainability. Develop your abilities to work with environmentally-friendly chemicals, processes and equipment to reduce your company’s carbon footprint while delivering its products and services.

As part of continuing education (CE) and career progression, you may pursue a degree in chemical technology or chemical engineering to learn about manufacturing and production through chemical processes. You would learn to design equipment, systems and processes used to refine raw materials and mix, compound and process chemicals. Higher academic qualifications in chemistry would give you in-depth knowledge about the science and properties of substances, their chemical composition and structure, and the chemical processes and transformations they undergo.

What Are Chemical Processes?

The modification of one or more chemicals or chemical compounds through chemical reactions is typically referred to as a chemical process. Whether self-occurring or triggered by external forces, chemical processes involve chemical reactions. 

Chemical manufacturing uses chemical processes to synthesise chemicals from raw materials or chemical feedstocks. The product formula specifying one or more ingredients that go into the composition of chemical products facilitates the manufacturing process.

The typical steps in a chemical process at manufacturing plants are as follows:

• Raw material/feedstock/intermediate product storage
• Feed preparation and purification
• Reaction (in the reactor)
• Product separation
• Product purification
• Product packaging, storage, and transport

Some Skills Required by Chemical Operators

Chemical Operators must possess a thorough knowledge of chemical reactions and the physics involved, as well as of the process technology to transform matter. They must understand plant equipment & utilities, measuring and controlling process variables, and computer control systems. Strict adherence to safety procedures to prevent harm to people, resources and the environment and keep legal claims at bay is as crucial as training to deal with emergencies. 

Chemical Operators must be skilled at safely handling fixed and rotating process equipment and hazardous materials. They must be thorough with valve types & operations, pumps & fluid flow, heat exchangers, reactor operations, and distillation & stripping. They must also understand basic process instrumentation. Last but not least, they must comply with quality assurance standards on the shop floor, following GMPs and department SOPs at all steps in the production process. 

Reasoning and problem-solving abilities to troubleshoot and carry out work safely and efficiently are critical skills for Chemical Operators. Clear and precise communication and the ability to strictly follow oral and written instructions can help avoid accidents and damage. You must develop and exercise concentration and attention to detail, as one moment of negligence can disrupt the plant and its processes. Time management will help you meet strict production deadlines. Confined space training, Lock Out Tag Out training, and Microsoft Suite proficiency are also handy for Chemical Operators.

Some Roles in the Field of Chemical Operations 

Specific titles of the roles Chemical Operators play in the industry may depend on the equipment, process or chemical substance they handle. Some roles are as follows:

• Reactor Operator
• Tower Operator
• Mixer Operator
• Dissolver Operator
• Devulcaniser Operator
• Emulsification Operator
• Hydrogenation Operator
• Precipitation Equipment Tender
• Badger Distiller Operator
• Ammonia Still Operator
• Acid Plant Operator
• Nitric Acid Plant Operator
• Nitrogen Operator
• Water Treatment Plant Operator
• Chemical Treatment Plant Technician
• Naphtha Washing System Operator
• Pharmaceutical Process Operator
• Polymer Process Operator
• Refinery Process Operator
• Renewable Fuels Process Operator

The source of a chemical substance, whether manufactured or natural, does not alone reveal its toxicity. A key aspect in evaluating harmful chemicals is their dose, whether in a potato or a product.

Versatility could be the middle name of Chemical Operators. They tackle various duties, from handling chemical products and running processing machines to operating computerised systems and supervising plant personnel. Yours is a dynamic production floor job that demands technical expertise, meticulous attention to detail and quick responses and contributes to keeping the wheels of production and manufacturing operations well-oiled and running smoothly.

Safety is your priority. Thoroughly read and understand standard operating procedures and health & safety policies and regulations. Be thorough in manual and equipment operations. Have a solid grasp of material flows, operating conditions, process & instrumentation diagrams, and interlock & safety systems. Wear safety gear and do not attempt a task without training. Handle chemicals only after reading relevant safety data. Understand hazard symbols and know where hazardous and inflammable materials are stored