Lead Process Engineer for FOAK SAF Pilot & Scale-Up

PetsApp; Cambridge (MA); On-site; USD 180,000 - 270,000; Full time

Benefits offered by this job

Competitive salary

Incentive Stock Options

Medical, dental, and vision benefits

401k match

Commuter benefits

Job summary

Sora Fuel seeks a Principal Process Engineer to lead FEED and detailed design for our FOAK SAF pilot plant, integrating DAC, water/CO2 electrolysis with FT synthesis. You will own BOP engineering, drive safety, and ensure scale-up from demonstration to pilot deployment.

Requires 15+ years of process engineering in petrochemicals or industrial gas, strong HAZOP/LOPA experience, and ability to coordinate with EPCs. Competitive compensation and stock options offered.

Qualifications

• Master’s degree in Chemical Engineering; Ph.D. preferred.
• 15+ years process engineering experience in oil & gas, petrochemicals, refining, or industrial syngas/hydrogen production.
• Proven track record of taking complex chemical processes from pilot/demonstration scale to a First-of-a-Kind commercial facility.
• Extensive, hands‑on experience participating in and leading HAZOP, HAZID and LOPA studies for chemical systems
• Proficiency in process simulation software.
• Ability to collaborate with EPCs to ensure pilot system integration into existing infrastructure.
• Strong communication in a fast-paced, collaborative team environment.
• Core values alignment with transparency, diversity, collaboration, valuing people and development, and work ethic.

Responsibilities

• Lead the front‑end engineering design (FEED) and detailed engineering for the SAF facility’s Balance of Plant.
• Design and optimize auxiliary systems, including water treatment, utility gas, and product storage.
• Develop, review, and approve critical engineering documents, including PFDs, P&IDs, heat and mass balances (HMB), and control narratives.
• Optimize complex thermal integration networks to maximize energy efficiency across DAC, electrolysis, and exothermic FT synthesis loops.
• Own the technical interfaces between the DAC unit, electrolyzer stacks and the Fischer-Tropsch synthesis island.
• Resolve integration challenges related to transient operations, gas compositions, pressure matching, and recycling loops.
• Collaborate closely with technology vendors, EPC partners, and internal R&D teams to ensure equipment specifications align with system requirements.
• Serve as the lead technical authority for process safety management, including HAZOP, HAZID, and LOPA reviews.
• Ensure all designs comply with relevant industrial codes, environmental regulations, and aviation fuel standards (e.g., ASTM D7566).
• Provide on-site engineering support during construction, commissioning, and startup.
• Troubleshoot operational bottlenecks and establish process monitoring frameworks for early-stage production data.

Skills

Process engineering

HAZOP/HAZID/LOPA

Process safety

BOP design

FEED & Detailed design

PFDs & P&IDs

EPC coordination

Process simulation software

Cross-functional communication

Education

Master's in Chemical Engineering

PhD preferred

Tools

Process simulation software

Job description

Sora Fuel seeks a Principal Process Engineer to lead FEED and detailed design for our FOAK SAF pilot plant, integrating DAC, water/CO2 electrolysis with FT synthesis. You will own BOP engineering, drive safety, and ensure scale-up from demonstration to pilot deployment.

Requires 15+ years of process engineering in petrochemicals or industrial gas, strong HAZOP/LOPA experience, and ability to coordinate with EPCs. Competitive compensation and stock options offered.