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Fort Lupton, Colorado, United States
Onsite
Available
About the Role
We're looking for a Senior Process Development Engineer to join our Pyrolysis Test Engineering team. Reporting to the Director of Pyrolysis, you will lead the development and scale-up of next-generation biomass conversion processes from pilot testing through commercial deployment. You will define experimental strategy, drive resolution of complex scale-up challenges, and provide technical leadership across R&D, Engineering, and Operations teams.
This role requires deep process engineering expertise, strong technical judgment, and the ability to translate ambiguous experimental findings into robust, scalable industrial processes.
Lead development of next-generation Charm pyrolyzers and biomass conversion processes to maximize bio-oil yield, product quality, reliability, and economic performance.
Define test plans and experimental campaigns that address critical technical uncertainties and inform commercialization decisions.
Own investigation and resolution of complex process performance, operability, and scale-up challenges across pilot and demonstration systems.
Develop and validate process models, material and energy balances, and engineering analyses to guide process improvements and future facility design.
Lead interpretation and communication of experimental results to technical and non-technical stakeholders, including recommendations for strategic development priorities.
Prepare and review process engineering documentation including Process Flow Diagrams (PFDs), Piping and Instrumentation Diagrams (P&IDs), Process Control Narratives (PCNs), Standard Operating Procedures (SOPs), and process equipment specifications.
Lead or facilitate process safety activities including Hazard and Operability study (HAZOP), Failure Mode and Effects Analysis (FMEA), Management of Change (MOC) reviews, and commissioning/startup readiness reviews.
Partner closely with Mechanical, Automation, Electrical, Manufacturing, and Operations teams to ensure successful deployment and operation of new process technologies.
Mentor junior engineers and contribute to the development of engineering standards, best practices, and technical culture across the organization.
Support our 24/7 operations through a rotating after-hours coverage schedule, totaling approximately 2–3 weeks per year.
Bachelor's degree in Chemical Engineering, Mechanical Engineering, or a related field.
7+ years of experience in process development engineering, or scale-up engineering, including significant experience operating and developing pilot-scale systems.
Demonstrated success scaling chemical, thermochemical, energy, or industrial process technologies from pilot through commercial deployment.
Deep understanding of heat transfer, reaction engineering, mass and energy balances, process controls, process safety, and industrial operations.
Strong hands-on troubleshooting skills and the ability to diagnose complex process and equipment failures in ambiguous environments.
Experience leading cross-functional technical projects involving multiple engineering disciplines.
Excellent written and verbal communication skills, including the ability to influence technical direction and align diverse stakeholders.
Strong engineering judgment and ability to balance technical rigor, operational realities, schedule, and cost.
Excitement for scaling industrial technologies that can meaningfully impact climate change.
M.S. or Ph.D. in Chemical Engineering, Mechanical Engineering, or a related field.
Experience with pyrolysis, gasification, biomass conversion, refining, petrochemicals, renewable fuels, or other thermochemical processing technologies.
Experience commissioning and operating industrial process systems at demonstration or commercial scale.
Experience leading process hazard analyses and implementing process safety management programs.
Experience managing external engineering partners, equipment vendors, or contract manufacturers.