Sr. Process Development Engineer - Pyrolysis Test

Senior Process Development Engineer

Our mission is to return the atmosphere to 280 ppm CO₂. We convert excess inedible biomass into carbon-rich bio-oil and inject it into underground storage for permanent carbon removal. At scale, we can use bio-oil to make fossil-free iron.

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.

Your Responsibilities

• 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.

You Bring

• 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.

Bonus if you Bring

• 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…