Senior Process Engineer
About The Position
Oxylus Energy is a climate-tech company developing electrochemical technology that converts carbon dioxide into carbon-neutral fuels and chemicals. The Senior Process Engineer will lead process design for integrated systems, own the balance of plant for CO₂ electrolyzers, and develop the strategy for integrating electrolyzer technology with downstream thermal heterogeneous catalysis. The role will define process architecture from laboratory demonstrations through pilot and eventual commercial plants. The position is hands-on and involves designing, building, and operating high-pressure reactor systems and pilot equipment. The engineer will lead process hazard analyses, guide scale-up decisions, mentor other engineers, and work closely with electrochemists, materials scientists, mechanical and controls engineers, and company leadership. The role also represents Oxylus Energy’s process technology to external partners. Safe design and operation are central because the systems handle pressurized and hazardous gases, including CO and H₂. The role is based on-site in Branford, Connecticut. The successful candidate must be willing to relocate to the Bridgeport/Stamford area within one year of the start date.
Requirements
- Degree in Chemical Engineering or a related field.
- Relevant experience by education level: B.S. with 7 or more years, M.S. with 5 or more years, or Ph.D. with 2 or more years.
- 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 equipment codes, such as ASME Boiler and Pressure Vessel Code Section VIII and ASME B31.3.
- Experience leading process hazard analyses for pressurized, flammable, or toxic gas systems.
- Proficiency with process simulation tools such as Aspen Plus or Aspen HYSYS.
- Experience mentoring engineers or leading small technical teams.
- Strong attention to detail, problem-solving, and organizational skills.
- Excellent written, verbal, and presentation skills.
- Must be willing to relocate to the Bridgeport/Stamford area within one year of the start date.
Nice To Haves
- Direct experience with syngas conversion, such as Fischer–Tropsch or methanol synthesis.
- Experience scaling processes from laboratory to pilot or demonstration plants.
- Experience with gas separation technologies, such as pressure swing adsorption (PSA) or membrane separation.
- Experience with techno-economic analysis or life-cycle assessment.
- Familiarity with electrolyzers or other electrochemical systems.
Responsibilities
- Define and own process architecture for integrated electrolyzer and thermal catalytic systems, from laboratory scale through pilot plant design.
- Own balance-of-plant design, including CO₂ supply and conditioning, gas separation and purification, compression, water management, heat integration, and product handling.
- Lead integration of the electrolyzer with downstream heterogeneous catalytic processes, including stream matching, recycle strategies, and overall process efficiency.
- Lead the design, construction, 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 ensure designs comply with applicable codes and standards for high-pressure and hazardous-gas systems.
- Drive techno-economic analysis and scale-up planning, identifying 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.
Benefits
- Competitive salary.
- Medical, dental, and vision coverage.
- Paid sick days and vacation.
- 401(k) match.
- A diverse and inclusive work environment.
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What This Job Offers
Job Type
Full-time
Career Level
Senior
