Lead Engineer, Process Design

AIRCO; Doylestown (Bucks County); On-site; USD 150,000 - 210,000; Full time

Benefits offered by this job

Health benefits

HSA & FSA

401(k) with company match

Short-Term Disability

Paid time off

Wellness programs

Job summary

AIRCO is seeking a Lead Engineer, Process Design to provide technical leadership in flowsheet development, process simulation, mass/heat balance generation, equipment selection, and PFDs/P&IDs. This role is based in New Britain, PA, on-site three days per week and reports to the Manager of Engineering.

You will collaborate across R&D, operations, and EPC partners, drive process design standards, and mentor teams while ensuring compliance with EH&S guidelines and project objectives.

Qualifications

• Bachelor's degree in chemical engineering; advanced degree preferred.
• 10–15 years design experience in refining, petrochemical, chemical, gas processing or related industries.
• Expertise with Aspen Plus and HYSYS for process simulation.
• Experience generating material and heat balances, PFDs, P&IDs, datasheets, hydraulics, and design packages.
• Strong understanding of equipment design, sizing and selection.

Responsibilities

• Lead the development of Process Design Packages for AIRCO's technologies for FEL, FEED and detailed engineering.
• Lead process synthesis, simulation, material/heat balance, equipment selection and PFD/P&ID generation.
• Serve as the primary process-engineering liaison among R&D, operations, EPC contractors, customers, and other disciplines.
• Support process-economic evaluations, cost estimates, and technical decisions with clear communication of assumptions and risks.
• Ensure compliance with engineering standards, guidelines, and EH&S regulations for AIRCO techs and processes.
• Represent AIRCO in external meetings presenting engineering solutions and recommendations.
• Develop engineering standards, mentor teams, and promote safety and high-quality work.

Skills

Chemical engineering

Process design

PFDs & P&IDs

Equipment datasheets

Process hydraulics

Education

Bachelor's degree in chemical engineering

Advanced degree preferred

Tools

Aspen Plus

HYSYS

Job description

About AIRCO

AIRCO™develops advanced technologies for energy security and global resiliency. The company makes drop-in e-fuels that can power transportation across air, land, sea and space. Its modular MAD Fuel System ™ combines the company's proprietary catalysts, compact hardware, and locally available power to produce fuels to spec wherever they're needed, turning distributed energy into ready-to-use fuel. Led by co-founder and CEO Gregory Constantine (a 2026 EY Entrepreneur of the Year), the company has been awarded government contracts, including from the U.S. Department of War, NASA and the Department of Energy (DoE), and has investment and commercial partners with groups such as In-Q-Tel, GE Aerospace, Toyota Ventures, Virgin Atlantic, JetBlue and Alaska Airlines among others.

The Position

We are seeking a Lead Engineer, Process Design to join our team. This role will report to our Manager of Engineering. This position will provide technical leadership on engineering flowsheet development, process simulation and design, process mass and heat balance generation, process equipment selection and design, PFDs, P&IDs, equipment datasheets etc. This role will be a part of our Engineering department, and will work closely with our scientists, engineers, and operations team. This role is based in New Britain, PA and works on-site three days per week.

What you get to do

• Lead the development of Process Design Packages for new technologies developed by AIRCO research and development organization. These packages will provide the technical basis for FEL, FEED, and detailed engineering performed by EPC contractors.
• Lead process synthesis, simulation and design, generation of material & heat balance, equipment selection and design, PFD and P&ID generation, equipment data sheet generation, process hydraulics calculation, HAZOP reviews for commercial units based on carbon dioxide conversion technologies developed by AIRCO
• Serve as the primary process-engineering liaison among R&D, operations, EPC contractors, customers, and other engineering disciplines throughout project development, construction support, commissioning, and startup
• Support process-economic evaluations, cost estimates, project planning, and technical decision making by clearly communicating assumptions, findings, risks, and recommendations
• Ensure compliance with applicable engineering standards, internal design guidelines, and environmental, health and safety regulations for all the AIRCO developed technologies and processes.
• Represent AIRCO in external meetings and present engineering solutions, technical recommendations, and process-design packages.
• Develop engineering standards and work practices, mentor internal teams, and promote a safe, collaborative, and high-quality engineering environment.

What you bring to AIRCO

• Bachelor's degree in chemical engineering required; advanced degree preferred
• 10-15 years of design experience in refining, petrochemical, chemical, gas processing, or a related process industry.
• Expertise in industry-standard process simulation modeling: Aspen Plus, HYSYS
• Expertise in generating commercial scale heat and material balances, PFDs, P&IDs, equipment specifications, datasheets, hydraulics, and Process Design Packages.
• Strong knowledge of process equipment design, development, sizing, and selection.

Working at AIRCO - In addition to standard medical and dental benefits, that kick in Day 1, we provide:

Comprehensive Health Benefits

• Full coverage for employee base premiums on health, dental, and vision insurance.
• 70% coverage for spouse and dependent base premiums.
• Choose between base plans or enhanced options to fit your needs.

Health Savings & Flexibility

• Access company-sponsored HSA and FSA accounts to save on healthcare and dependent care expenses.

Income Protection & Insurance

• Company-paid Short-Term Disability insurance.
• Optional Long-Term Disability and Life Insurance plans.

Time Off & Leave

• Flexible and generous paid time off, with opportunities to carry over unused PTO.
• Paid family leave to support you during important life moments.

Retirement Savings

• Tax-deferred 401(k) plan with a 3% company match to help you invest in your future.

Lifestyle & Commuter Benefits

• Monthly Lifestyle Spending Account: Company-funded monthly benefit that can be used toward eligible work-from-home and commuting expenses, including gas, parking, and public transit.
• Pre-Tax Commuter Benefits: Access to pre-tax savings through Navia for eligible transit and parking expenses.

Additional Perks

• Ancillary benefits through Sequoia, including pet insurance and financial wellness programs.
• Employee wellness program to support your well-being. Inclusive of Wellhub & One Medical.
• Company-sponsored events and programs that promote an inclusive and values-driven workplace.
• Weekly company-funded meal stipend that can be used toward meals from restaurants and food delivery services.

At AIRCO we value employees for their unique perspectives. We are an inclusive affirmative action Equal Employment Opportunity employer. We consider applicants without regard to actual or perceived race, color, creed, religion, national origin, ancestry, citizenship status, age, sex or gender (including pregnancy, childbirth, pregnancy-related conditions, and lactation), gender identity or expression (including transgender status), sexual orientation, marital status, military service and veteran status, present or past history of intellectual, learning, mental, or physical disability (including but not limited to blindness) unless AIRCO determines that such disability prevents performance of the work involved, genetic information, or any other characteristic protected by applicable federal, state, or local laws and ordinances.

Don't meet every single requirement? Studies have shown that women, marginalized genders and people of color are less likely to apply to jobs unless they meet every single qualification. At AIRCO we are dedicated to building a diverse, inclusive and authentic workplace, so if you're excited about this role but your past experience doesn't align perfectly with every qualification in the job description, we encourage you to apply anyways. You may be just the right candidate for this or other roles

This position requires access to technology, software and other information that is subject to governmental access control restrictions, due to export controls, security classification and/or designation as Controlled Unclassified Information. Employment in this position is conditioned on the candidate’s ability to obtain and maintain appropriate government authorization to access technology or information, to the extent required, including without limitation a security clearance, export license, or other documentation required to establish authorization to receive access to such items technology or information.

We may delay commencement of employment, rescind an offer of employment, terminate employment, and/or modify job responsibilities, compensation, benefits, and/or access to Company facilities and information systems, as we deem appropriate, in order to ensure compliance with applicable government access control restrictions.

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