Development Engineer: Electric Heating & Catalytic Heaters

Hyca Heat; United States; Hybrid; USD 81,000 - 138,000; Full time

Benefits offered by this job

Hybrid work arrangement

VSOP participation

Competitive compensation

Job summary

Hyca Heat is seeking an experienced Development Engineer to design and develop electric high-temperature heating systems for process gas heaters. You will own the electric resistance heating core, where the conductor also serves as the catalyst support, blending heating, heat transfer, and catalytic combustion in one component.

The role demands deep thermomechanical knowledge, material selection under real atmospheres, and collaboration across R&D to move from prototype to series production.

Qualifications

• Degree or technician qualification in mechanical/energy/materials engineering or related field.
• Several years of industry experience in electric resistance heating design or related heating systems.
• Experience with heating conductor structures and their impact on surface load, flow, and life.
• Strong materials and thermomechanical understanding for high-temperature components.
• Fluent German (C1/C2) and very good English.

Responsibilities

• Design electric resistance heaters and process gas heaters, focusing on surface load, conductor temperature, resistance and heat transfer in gas-flow systems.
• Select materials under real atmospheres (FeCrAl, NiCr alloys) for oxidation, carburization, corrosion and sulfur/steam effects.
• Design heating conductor structures to support catalysts, considering coating adhesion and aging.
• Address thermomechanics: thermal expansion, creep, fatigue, and hot-spot avoidance.
• Plan testing, run rigs, analyze failures, and support commissioning and customer acceptance.
• Oversee development from prototype to series production and manage suppliers.

Skills

Electric heating design

Heat exchanger design

Materials understanding

Thermomechanics knowledge

FEM/CFD simulation

Python/MATLAB for calculations

English proficiency

German language proficiency

Education

Bachelor/Master or Techniker in mechanical/energy/materials engineering

Tools

FEM/CFD

CAD

Job description

Hyca Heat is seeking an experienced Development Engineer to design and develop electric high-temperature heating systems for process gas heaters. You will own the electric resistance heating core, where the conductor also serves as the catalyst support, blending heating, heat transfer, and catalytic combustion in one component.

The role demands deep thermomechanical knowledge, material selection under real atmospheres, and collaboration across R&D to move from prototype to series production.