Thermal Mechanical Engineer

Thermal Mechanical Engineer

Baltimore, MD Full-time

ETCH is a startup commercializing a radically new and efficient decarbonization technology for the simultaneous greenhouse gas-free production of hydrogen and solid carbon from natural gas.

Primary duties include leading the design and development of advanced reactor systems and supporting infrastructure. This role will be central to scaling from pilot to commercial systems, with a strong emphasis on reactor bundles, high-temperature design, and balance-of-plant (BOP) integration. Focus will be on design, improving performance and efficiency, and safety of the processes all while driving continuous improvements and innovations.

Other duties include:

Reactor & Core System Design

• Design and optimize annulus reactor bundles, including thermal uniformity, flow distribution, and mechanical integrity
• Develop detailed mechanical designs for pilot reactor modifications and scale-up to 5 MTPD (metric tons per day) reactor systems
• Perform thermal and structural calculations for high-temperature operation (≥1000°C environments)
• Evaluate materials of construction considering creep, thermal expansion, and chemical compatibility

Structural & Mechanical Systems

• Design structural supports for reactor systems, accounting for thermal expansion, vibration, and load conditions
• Ensure mechanical robustness and maintainability of reactor assemblies
• Develop expansion joints, supports, and interfaces between hot and cold sections

Balance of Plant (BOP) & Layout

• Lead mechanical design and layout for balance-of-plant systems, including:
• Heat exchangers
• Piping systems
• Valves and flow control
• Gas handling systems
• Develop plant layout and equipment arrangement for pilot and commercial facilities
• Ensure proper integration between reactor core and BOP systems

Engineering Analysis & Optimization

• Conduct thermal modeling (CFD/FEA preferred) and heat transfer analysis
• Perform stress analysis and lifecycle evaluation of critical components
• Support optimization of system efficiency, uptime, and reliability

Execution & Scale-Up

• Support transition from pilot to commercial-scale systems
• Work closely with fabrication teams, vendors, and operations
• Participate in installation, commissioning, and troubleshooting

Qualifications:

• Education:
  
  Bachelor's or Master's degree in Mechanical Engineering or related field
• 5+ years of experience in:
  High-temperature systems, Reactor design / process equipment, Thermal systems engineering
• Experience with chemical plants, hydrogen systems, pyrolysis, or similar is highly preferred
• Strong fundamentals in:
  Heat transfer, Fluid mechanics, Structural mechanics Experience with:
• CAD tools (Solid Works, Inventor, or similar)
• FEA/CFD tools (ANSYS, COMSOL, etc.)
• High-temperature alloys, ceramics, and refractory materials
• Pressure systems and piping design codes (ASME preferred)

Preferred Attributes

• Experience designing modular or bundled reactor systems
• Familiarity with scale-up challenges (pilot → commercial)
• Hands-on mindset with ability to work in fast-paced startup environments
• Strong problem-solving and ownership attitude

An ability to work independently as well as in a team environment toward timely execution of goals is required.

Compensation commensurate with relevant experience.