Senior Process Engineer- Hydrogenation Scale-Up
Location: Remote or Chicago, IL
Salary Range: $150,000 – $190,000
Experience: 15+ Years
Overview
We are seeking an experienced Senior Process Engineer to lead the scale-up and optimization of complex chemical processes from development through piloting and commercial deployment. This role will collaborate closely with internal Research & Development and Manufacturing teams, as well as external technology providers, suppliers, or partners.
The ideal candidate brings deep expertise in chemical process engineering, process modeling, cost analysis, and scaling processes safely and efficiently in industrial settings.
Key Responsibilities
Process Development & Scale-Up
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Lead scale-up of chemical processes from laboratory and pilot scale to commercial production.
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Develop process flow diagrams, mass and energy balances, and detailed process models.
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Define operating conditions, reactor configurations, and process integration strategies.
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Identify and mitigate scale-up risks related to reaction kinetics, heat and mass transfer, catalyst performance, or safety.
Experimental Planning & Execution
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Collaborate with R&D and Manufacturing teams to design and execute experimental and pilot-scale plans.
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Translate lab-scale data into pilot and commercial-scale design inputs.
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Oversee pilot trials, analyze results, and iterate process designs based on findings.
External Partner & Technology Management
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Serve as the technical lead interfacing with external partners, suppliers, or licensors.
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Coordinate development efforts with multiple external partners as needed.
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Plan and execute testing campaigns at partner or third-party facilities.
Technoeconomic Analysis & Cost Modeling
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Develop and maintain process and cost models to evaluate performance and scale-up scenarios.
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Estimate CAPEX and OPEX for pilot-scale and industrial deployment.
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Assess trade-offs between alternative technologies, catalysts, or process configurations.
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Support investment decisions, partner selection, and commercialization strategies using data-driven analysis.
Cross-Functional Collaboration
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Partner with Manufacturing teams to ensure process designs are safe, practical, and operable at scale.
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Support process safety evaluations and risk assessments.
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Contribute to long-term manufacturing and scale-up roadmaps.
Qualifications
Required
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Bachelor’s degree or higher in Chemical Engineering or related field.
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15+ years of experience in chemical process engineering and scaling industrial processes.
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Hands-on experience transitioning pilot-scale operations to commercial-scale systems.
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Strong understanding of reactor design, catalysis, and process modeling.
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Experience managing multiple parallel development efforts and working with external partners or suppliers.
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Strong quantitative and analytical skills, including process modeling and cost estimation.
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Experience developing process design packages.
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Familiarity with process simulation tools such as Aspen, gPROMS, or similar platforms.
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Experience in industrial chemical manufacturing environments.