Staff Chemical Engineer, Thermal Processing Specialist

Position Summary:

We are seeking a highly experienced and technically proficient Staff Chemical Engineer - Thermal Process Specialist to lead the design, development, and optimization of high-temperature thermal processing systems for metallurgical applications. This role will serve as a Subject Matter Expert (SME) in high-temperature reactor and process design, providing critical insights into technology selection, system design, materials of construction, process control, and safety.

Key Responsibilities:

• Serve as the SME for high-temperature thermal processing technologies, with a focus on metallurgical applications

• Evaluate and compare thermal processing routes for a variety of feedstocks, identifying key design parameters, trade-offs, and performance metrics

• Direct development of new high-temperature processes, including bench-scale testing, pilot plant design, and scale-up strategies

• Scope and define bench-scale testwork programs, including selection of appropriate lab-scale equipment and test conditions to simulate industrial thermal processes

• Specify materials of construction for thermal reactors and associated systems, considering temperature, corrosion, erosion, and mechanical stresses

• Develop process control strategies for high-temperature systems, including instrumentation selection, control logic, and integration with plant automation systems

• Model and simulate thermal processes using process and thermodynamic modeling tools to predict system behavior, optimize performance, and support scale-up

• Analyze high-temperature chemical reactions, including molten phase behavior, combustion chemistry, and solid-gas interactions relevant to metallurgical processes

• Prepare and review detailed engineering documentation, including:

• Block Flow Diagrams (BFDs)

• Process Flow Diagrams (PFDs)

• Heat and Mass Balances

• Equipment Specifications

• Engineering Calculations

• Piping and Instrumentation Diagrams (P&IDs)

• Participate in HAZOP studies and other process safety reviews to identify and mitigate hazards associated with thermal systems

• Collaborate with safety and compliance teams to ensure thermal systems meet internal and external safety standards, including combustible dust, flammable gases, and thermal runaway risks

• Provide technical support during commissioning, startup, and troubleshooting of thermal processing systems

Required Qualifications:

• 10-15 years of experience in high-temperature processing systems (>500°C) within a metallurgical or related industrial environment

• Proven expertise in the design, commissioning, and operation of a wide range of thermal processing equipment, including:

• Kilns

• Furnaces

• Dryers

• Roasters

• Strong background in material handling, feed/discharge systems, off-gas treatment, and dust collection associated with high-temperature operations

• Experience with both direct-fired and indirect-fired thermal systems

• Minimum 5 years of experience linking engineering design with bench and pilot-scale testing to develop and optimize thermal processes

• Direct experience in selecting and qualifying ceramic and metallic materials for use in high-temperature systems

• Proficiency in process modeling (HSC Chemistry, METSIM, Aspen, or similar) and thermodynamic simulation software (FactSage, MPE or similar)

• Deep understanding of process safety and hazard mitigation strategies for high-temperature operations

• Familiarity with relevant regulatory codes and standards (e.g., ASME, NFPA) governing thermal systems and fuel delivery infrastructure

• Strong understanding of combustion, pyrolysis, and phase transformation phenomena in high-temperature environments

• Familiarity with thermal system safety standards, including combustible dust mitigation, refractory failure modes, and emergency venting design

Physical Requirements:

• Ability to safely perform job duties in both office and production environment
• Must be able to lift and carry up to 50 lbs. as needed
• Must maintain regular and punctual attendance in alignment with company and regulatory standard.
• Must be able to communicate clearly

Working Conditions:

• Split work environment between office and the production facility
• Work may involve extended periods of working in the production facility
• Ability to work in challenging working conditions which may include exposure to noise, dust, chemicals, and temperature extremes, while protected by PPE, for extended periods of time
• May require occasional work weekends or alternate shifts to support production needs