Senior Process Engineer (Hydrogenation & ScaleUp)

Job Title: Senior Process Engineer (Hydrogenation & Scale-Up)
Job Type: Permanent, Full-time
Work Schedule: Remote with Occasional Travel
Sector: Alternative Fuels, Specialty Chemicals
Location: Remote within US, but preference for Chicago, IL, San Diego, CA, or Houston, TX
Reporting to: Chief Manufacturing Officer

NES Fircroft is a leading global technical recruitment company providing professional contract and permanent staff to a diverse world-wide client base within the energy industry. Our client, a a pioneering start-up with innovative biotechnology that will create a sustainable pathway for alternative fuels, has a permanent opportunity for a Senior Process Engineer (Hydrogenation & Scale-Up) to be based in Chicago, IL, San Diego, CA, or Houston, TX.

Position Summary
 
We are seeking an experienced Senior Process Engineer to lead the scale-up of a multi-step catalytic hydrogenation process from laboratory development through pilot-scale validation and into industrial deployment. This role will serve as a technical bridge between R&D and Manufacturing and will work extensively with external technology licensors, catalyst suppliers, and joint venture partners.
 
The ideal candidate has a proven track record of translating lab-scale data into pilot and commercial designs, with strong expertise in catalytic hydrogenation, process modeling, and technoeconomic analysis for complex, multi-intermediate chemical systems.

Key Responsibilities
 
Process Development & Scale-Up

• Lead the scale-up of hydrogenation processes from laboratory and pilot scale to full industrial production.
• Develop process flow diagrams (PFDs), mass and energy balances, and detailed process models for multi-step hydrogenation systems.
• Define operating conditions, reactor configurations, and process integration strategies across multiple hydrogenation steps and intermediates.
• Identify, assess, and mitigate scale-up risks related to reaction kinetics, heat and mass transfer, catalyst performance, and process safety.

 
Experimental Planning & Execution

• Partner closely with internal R&D and Manufacturing teams to design and execute experimental programs for catalyst screening, process optimization, and scale-up validation.
• Translate lab-scale and bench data into pilot-scale and commercial-scale design inputs.
• Oversee pilot trials, analyze results, and iterate process designs based on experimental data and performance metrics.

 
External Partner & Technology Management

• Act as the technical lead interfacing with external technology licensors and industrial-scale catalyst suppliers.
• Coordinate work across multiple external partners concurrently, where different technologies or catalysts may be employed across the end-to-end process.
• Collaborate with partners to define pilot and commercial unit sizing, operating envelopes, and catalyst requirements.
• Plan and execute catalyst testing campaigns at partner pilot facilities or third-party sites.
• Lead technical evaluations and development activities conducted at joint venture partner facilities.

 
Technoeconomic Analysis & Cost Modeling

• Develop and maintain technoeconomic models to evaluate process performance, scale-up scenarios, and key cost drivers.
• Estimate CAPEX and OPEX for pilot facilities and full commercial deployment, including reactors, hydrogen supply systems, utilities, and downstream operations.
• Evaluate trade-offs between alternative catalysts, process configurations, and external partners from both technical and economic perspectives.
• Support commercialization strategies, partner selection, and investment decisions through rigorous, data-driven analysis.

 
Cross-Functional Collaboration

• Partner with Manufacturing to ensure process designs are practical, safe, and operable at commercial scale.
• Support process safety activities, including HAZOPs and risk assessments related to hydrogenation operations.
• Contribute to long-term manufacturing, scale-up, and technology deployment roadmaps.

 
Qualifications:

• Bachelor’s degree or higher in Chemical Engineering.
• Demonstrated experience scaling catalytic chemical processes, preferably hydrogenation.

• Experience developing process design packages (PDP), detailed design, FEED studies, HAZID/ HAZOPS, equipment data sheet specifications, etc.

• Proficiency with process simulation tools (e.g., Aspen, gPROMS, or similar.
• Experience designing and taking process models to design a Pilot unit.
• Hands-on experience with pilot-scale operations and transition to commercial-scale systems.
• Experience working with external technology licensors, catalyst suppliers, and/or joint venture partners.
• Ability to manage multiple parallel development efforts across different process steps and stakeholders.
• Strong quantitative skills, including technoeconomic modeling and cost estimation.
• Experience operating in or supporting industrial chemical manufacturing environments is a plus.

 
Desired Attributes:

• Experience working with Startups is a plus.
• Experience working with challenging technologies is a plus.
• Highly collaborative with the ability to work effectively across internal teams and external organizations.
• Strong communication skills with the ability to translate complex technical concepts to diverse audiences.
• Willingness to travel to partner, pilot, and joint venture facilities as required.

  
Why work here
 

• Growth in a Fast-Paced Environment – Join a pioneering, growing start-up at the forefront of synthetic biology, fuel innovation, and sustainability.
• Be Part of Cutting-Edge Biotech Innovation – Be part of a cutting-edge biotech company engineering enzymes to revolutionize alternative fuel.
• Mission-Driven Impact – Help drive the transition to cleaner, more efficient energy sources by developing breakthrough biotechnologies.
• Collaborative & Inclusive Culture – Work in a team-oriented environment that values diversity, equity, and inclusion.
• Work with Industry Experts – Engage with top-tier scientists, researchers, and business leaders at the forefront of alternative fuel innovation.
• Competitive Compensation & Benefits – Enjoy market-leading salary packages, comprehensive health benefits, 401(k) match, and more.

 
This is an excellent opportunity to join a pioneering start-up with innovative biotechnology that will create a sustainable pathway for alternative fuels. The successful applicant will receive a competitive compensation package, annual bonus, comprehensive medical benefits, PTO, holidays, and more. Candidate must have authorization to work in the U.S. without a visa or ongoing work permit. Visa sponsorship is not offered. For more information on this opportunity or others, please contact Mishu Ventura.


With over 90 years' combined experience, NES Fircroft (NES) is proud to be the world's leading engineering staffing provider spanning the Oil & Gas, Power & Renewables, Chemicals, Construction & Infrastructure, Life Sciences, Mining and Manufacturing sectors worldwide. With more than 80 offices in 45 countries, we are able to provide our clients with the engineering and technical expertise they need, wherever and whenever it is needed. We offer contractors far more than a traditional recruitment service, supporting with everything from securing visas and work permits, to providing market-leading benefits packages and accommodation, ensuring they are safely and compliantly able to support our clients.