Staff Process Engineer

Commonwealth Fusion Systems•Devens, MA

19h•$152,000 - $230,000•Onsite

About The Position

Commonwealth Fusion Systems (CFS) is seeking a Staff Process Engineer to help design, build, commission, and operate commercially viable fusion power systems. The role requires deep chemical engineering fundamentals and extensive experience scaling up and operating systems in large industrial facilities such as power generation, LNG, petrochemicals, or cryogenics. The engineer will translate fundamental requirements into practical industrial systems and guide complex designs from early concepts through Front-End Loading (FEL), detailed engineering, construction, and operation. The engineer will work across cryogenics, power generation, molten salts, fueling, gas processing, vacuum systems, and utilities. As a domain expert, the role develops process design bases for loosely defined projects; prepares heat and material balances, equipment specifications, and P&IDs; leads process safety reviews; supports startup and commissioning; and troubleshoots operating systems. The position also provides technical leadership, manages project risks, and mentors less-experienced engineers. This is a full-time position with a stated salary range of $152,000–$230,000 per year, plus equity and benefits. The role is onsite and may involve occasional travel, nights, weekends, or on-call work. Work takes place in industrial, construction, commissioning, and operating environments, where hazards may include heat, cold, noise, fumes, strong magnets, lead, high voltage and current, pressure and vacuum systems, hazardous materials, and cryogenics. Employment offers are contingent on compliance with applicable U.S. export control laws.

Requirements

Bachelor’s degree in Chemical Engineering or a closely related discipline.
10 or more years of relevant industrial process engineering experience, potentially fewer with a Ph.D., or equivalent demonstrated depth of experience.
Deep domain expertise or broad expertise across domains, with demonstrated ability to independently own complex, semi-ambiguous work and seek support when needed.
Strong command of chemical engineering fundamentals and a track record of taking systems through a structured FEL or phase-gated development process.
Experience scaling loosely defined process requirements into commercial-scale equipment and facilities.
Expertise developing process engineering deliverables, including design bases, PFDs, P&IDs, and heat/material balances, and sizing or selecting industrial process equipment.
Hands-on experience commissioning, operating, and troubleshooting physical equipment alongside operators, using field observations to diagnose performance.
Proficiency with process simulation tools such as EcoSim, Aspen HYSYS/Plus, or AVEVA.
Extensive experience applying industry codes and standards, such as ASME B31.3, ASME BPVC Section VIII, and API 520/521, to establish design boundaries, fluid service classifications, operating envelopes, and relief/depressurization cases.
Strong background in process safety, hazard identification, risk analysis such as HAZOP, and relief system design.
Experience integrating cross-functional engineering disciplines and working directly with vendors, EPC organizations, or construction contractors.
Ability to independently manage medium risks, drive solutions for larger project risks, and exercise sound engineering judgment to ensure practical, commercially viable designs.
Values aligned with CFS values of integrity, execution, impact, and self-critique.
Ability to lift up to 50 pounds occasionally.
Ability to stoop, climb, type, stand, and sit for extended periods.
Willingness to occasionally travel or work required nights, weekends, or on-call, including occasional travel to suppliers, contractors, or operating facilities.
Willingness and ability to work hands-on in industrial, construction, commissioning, and operating environments.
Dedication to safety while working around potential hazards including heat, cold, noise, fumes, strong magnets, lead, high voltage, high current, pressure systems, vacuum systems, hazardous materials, and cryogenics.
Ability to comply with U.S. laws concerning export-controlled or protected technologies or information.

Nice To Haves

Experience with large-scale cryogenic systems, particularly supercritical or liquid helium, and industrial high-vacuum systems.
Background in large-scale process facilities such as power generation, petrochemical, LNG, industrial gases, or nuclear.
Expertise in steam systems, molten salt systems, or industrial gas processing, including purification, separation, or fueling.
Experience with large-scale utilities such as cooling water, chilled water, compressed/instrument air, or nitrogen.
Track record scaling first-of-a-kind technologies from pilot or demonstration scale to commercial operation.
Experience with dynamic process simulation and consequence analysis.
Professional Engineer license.

Responsibilities

Own process engineering scope for complex systems with loosely defined outcomes, guiding work from early concept through operation with near-complete independence.
Translate engineering requirements into commercially viable systems and develop process design bases, operating envelopes, PFDs, heat, material and utility balances, P&IDs, and process datasheets.
Apply chemical engineering fundamentals to resolve technical challenges and define operating boundaries.
Develop steady-state and dynamic process models to guide process design, system architecture, and equipment selection.
Size, specify, and evaluate process equipment, working with suppliers, fabricators, and multidisciplinary teams to assess performance, safety, and cost tradeoffs.
Drive engineering through a phase-gated design process, maturing systems from conceptual design to engineering definition.
Lead process safety activities, including HAZOPs, design reviews, and relief/depressurization studies; develop control philosophies and interlocks with controls engineers.
Support field execution by preparing work and commissioning plans, test procedures, and startup strategies, and participate in commissioning and performance testing.
Troubleshoot operating equipment using engineering fundamentals and field data, and apply lessons learned to process improvements, tools, and department policies.
Provide technical leadership, manage medium-to-large project risks by driving solutions, and mentor less-experienced engineers.