Senior Process Engineer

On-site, Branford, CT (must be willing to relocate to the Bridgeport/Stamford area within one year of the start date)

Oxylus Energy is a climate-tech company building solutions that can scale. Our breakthrough electrochemical technology converts carbon dioxide into low-carbon fuels and chemicals, reducing the world's dependence on fossil fuels. We are a team of scientists, engineers, and problem solvers working to make that future real.

As Senior Process Engineer, you will lead the process design of Oxylus' integrated systems. You will own the balance of plant for our CO₂ electrolyzers and set the strategy for integrating our electrolyzer technology with downstream thermal heterogeneous catalysis, turning CO-rich product streams into feed stocks for processes such as Fischer-Tropsch or methanol synthesis. You will define the process architecture that takes us from lab-scale demonstrations to pilot and, eventually, commercial plants.

You will remain hands-on, designing, building, and operating high-pressure reactor systems and pilot equipment. You will also lead process hazard analyses, guide scale-up decisions, and mentor other engineers. Because our systems handle pressurized and hazardous gases, including CO and H₂, safe design and operation are central to this role. You will work closely with our electrochemists, materials scientists, mechanical and controls engineers, and leadership, and represent our process technology with partners.

• Define and own the process architecture for integrated electrolyzer and thermal catalytic systems, from lab scale through pilot plant design.

• Own the design of the balance of plant, including CO₂ supply and conditioning, gas separation and purification, compression, water management, heat integration, and product handling.

• Lead the integration of our electrolyzer with downstream heterogeneous catalytic processes, including stream matching, recycle strategies, and overall process efficiency.

• Lead the design, build, and operation of high-pressure catalytic reactor systems, and direct catalyst evaluation for activity, selectivity, and stability.

• Develop reactor designs and process models, using kinetics, mass and energy balances, and heat-transfer analysis to size equipment and set operating conditions.

• Specify pumps, compressors, heat exchangers, separators, and other process equipment, and manage relationships with vendors, fabricators, and engineering firms.

• Own PFDs, P&IDs, heat and material balances, and equipment datasheets for integrated systems.

• Lead process hazard analyses, such as HAZOP, and make sure designs comply with applicable codes and standards for high-pressure and hazardous-gas systems.

• Drive techno-economic analysis and scale-up planning, and identify the process changes with the greatest impact on cost and performance.

• Mentor junior engineers, review their designs, and help grow the process engineering function.

• Present technical plans, risks, and results to leadership, partners, and funding agencies, and contribute to grant proposals and reports.

• A degree in Chemical Engineering or a related field, with one of the following:

  • B.S. with 7+ years of relevant experience.

  • M.S. with 5+ years of relevant experience.

  • Ph.D. with 2+ years of relevant experience.

• A track record of leading process design for high-pressure reactor systems from concept through commissioning and operation.

• Deep experience with heterogeneous catalysis, including catalyst testing and reactor performance analysis.

• Strong expertise in reactor design, kinetics, heat integration, and mass and energy balances.

• Experience specifying, operating, and troubleshooting pumps and compressors.

• Familiarity with pressure…