Senior Process Development Engineer

Who we are:  

Electra is reinventing ironmaking from the ground up with a breakthrough electrochemical technology that produces high purity clean iron and critical co-minerals. With two operating pilots in Boulder and a new demonstration facility underway in Jefferson County, we’re on track to reach commercial scale by the end of the decade. Backed by over $300 million and strategic partnerships with global leaders across mining, steel, and big tech, momentum is on our side.  Recognized by Fast Company as a Most Innovative Company and a Next Big Thing in Tech, and named one of TIME’s 100 Climate Leaders, we’re building a company shaping the future of industry. If you’re looking to make an impact and join a team that’s driven, focused, and scaling, we want to hear from you.

What you will do:  

The Senior Process Development Engineer on the process engineering team will contribute to the design and testing of chemical and hydrometallurgical processes across a variety of scales, from bench-scale proof-of-concept to Electra’s iron-refining pilot plant. 

Responsibilities include:

• Lead projects to study and scale up new processes at laboratory and pilot scale, including: designing new chemical processing systems, designing experiments to prove out novel concepts, and producing data to inform system scale-up 
• Designing new chemical process systems: developing mass and energy balances, drawing P&IDs, specifying equipment, and building systems 
• Contribute to process hazard analyses by contributing and leading HAZOPs, FMEAs, and other hazard reviews 
• Collaborate with mechanical and electrical engineers to effectively communicate design requirements for novel chemical processing systems 
• Collect and synthesize experimental data, and present results to guide engineering and business decisions 
• Commission and troubleshoot new equipment 
• Maintain a safe working environment and lead safety assessments of new equipment and operations 
• Read, understand, and comply with all workplace health and safety policies, safe work practices, and company policies and procedures 
• Perform other duties as assigned by supervisor 

What we need you to bring to the team:   

• Bachelor's degree in chemical engineering, mining/metallurgical engineering, or chemistry, or related  
• 8 years of industry experience in process design, including mass and energy balances, reaction kinetics, thermodynamics, separations, and fluid flow. (Excludes Internships and co-ops)
• Experience leading process-engineering projects and serving as a subject-matter expert
• Demonstrated success implementing safety measures for gas- and liquid-processing systems
• High proficiency with process simulation software and the ability to use models to inform experimental predictions
• Strong ability to analyze complex experimental data, recognize important patterns, and communicate results clearly to both technical and non‑technical teams
• Solid experience in analytical chemistry and applying it to troubleshoot challenging experimental issues and choose the right approaches
• Good working knowledge of fluid power systems, such as pumps, valves, and heat‑exchange equipment, and how they fit into larger mechanical or process setups
• Hands‑on experience using power tools and basic fabrication methods to build or modify custom equipment to support testing or development work
• Experience coordinating with external vendors, tracking progress, and ensuring contracted work is delivered accurately and on schedule
• Proficient in, or able to quickly pick up, Microsoft Office applications including Word, Excel, PowerPoint, Outlook, OneDrive, and SharePoint to create clear documentation and support project needs