Process Engineer - Graphite

Process Engineer - Graphite

Baltimore, MD

The Process Engineer will serve as the critical technical bridge between R&D and the execution organization (engineering, procurement, and construction) as a novel process moves from bench/pilot scale toward a commercial, integrated production system for the production of graphite from natural gas. This individual will work closely with the R&D team during process development, applying process engineering discipline — mass and energy balances, equipment sizing logic, safety and operability considerations, and scale-up principles — to guide experimental work toward a design that is not just scientifically sound but industrially executable.

As the process matures, this person will own the conversion of R&D findings into a fully integrated Process Flow Diagram (PFD) and mass/energy balance covering all inputs, outputs, utilities, and waste streams. They will then carry that technical ownership forward through detailed engineering, equipment procurement, and construction/commissioning, ensuring design intent is preserved and that field realities are fed back into the process design as needed.

This is a hands-on, cross-functional role suited to an engineer who is equally comfortable in a lab/pilot environment, at a P&w table, and on a construction site.

Phase 1 — R&D Partnership & Process Development

• Work side-by-side with R&D scientists/engineers to understand the chemistry, reaction kinetics, and unit operations underlying the novel process including designing and running experiments and analyzing data.
• Bring process engineering rigor to experimental design: identify what data (rates, conversions, yields, residence times, temperatures, pressures, phase behavior) will be needed to support later scale-up and equipment sizing.
• Develop preliminary mass and energy balances from lab/pilot data, identifying gaps, inconsistencies, or unrealistic assumptions early.
• Flag scale-up risks proactively (e.g., heat/mass transfer limitations, fouling, corrosion, off-gas handling, solids handling, reaction runaway potential) before they become costly late-stage discoveries.
• Support pilot-scale trials: help define and execute test plans, instrumentation needs, and success criteria that generate data usable for commercial design.
• Translate R&D's process understanding into a common technical language usable by engineering, safety, and operations stakeholders.

Phase 2 — Flowsheet Development & Basis of Design

• Own development of the integrated Process Flow Diagram (PFD), capturing all major process steps, equipment, and streams.
• Build and maintain a full mass and energy balance across the process, including all raw material inputs, utility demands (electricity, cooling, inert/process gases, water), products, byproducts, and waste/emission streams.
• Develop the Basis of Design document, including design capacities, operating envelopes, turndown requirements, and key assumptions.
• Identify and specify major equipment duties (reactors, furnaces, heat exchangers, separation equipment, gas handling systems, etc.) in coordination with equipment vendors and R&D.
• Lead or contribute to HAZID/HAZOP-style reviews at the flowsheet stage to identify safety, environmental, and operability risks early.
• Coordinate with utilities, EHS, and site engineering to ensure the flowsheet reflects real site constraints (utility availability, permitting limits, footprint, etc.).

Phase 3 — Detailed Engineering, Procurement & Construction Support

• Serve as the process engineering point of contact on the project team through front-end engineering design and detailed engineering, ensuring P&IDs, equipment datasheets, and control philosophy remain consistent with the approved process design basis.
• Review and approve vendor equipment proposals and datasheets for technical compliance with process requirements.
• Support procurement by providing technical input during RFQ development, bid evaluation, and vendor technical clarifications.
• Participate in design reviews (P& and 3D model reviews) representing the process perspective.
• Support commissioning and start-up planning, including development of startup/operating…