Process Engineer

Insight Global; San Leandro (CA); On-site; USD 150,000 - 230,000; Full time

Job summary

Insight Global seeks a senior process engineer to lead the scale-up of downstream gas-phase separations and a high-temperature reactor. You will design and commission from pilot data to a 100 ton-per-day facility, handling corrosive acid-gas service and multi-component separations.

You will be in the pilot bay, sizing equipment, and engaging vendors for alloys and internals, on site for commissioning. This role blends hands-on field work with design tools, requiring on-site collaboration with

Qualifications

• 5+ years of process engineering experience in gas separations or related acid-gas processing.
• Experience taking a condenser train, separations system, or reactor from bench through fabrication and commissioning.
• Strong knowledge of hot corrosive gas service and related materials.
• Materials selection experience for corrosive environments (nickel/high-nickel alloys, linings).
• Hands-on with unconventional or solids-bearing feedstocks is a strong plus.
• Direct experience designing, scaling, or operating condensation, desublimation or high-temp reactors.
• Proficiency in process modeling tools (Aspen Plus, HSC, FactSage).
• Analytical methods (ICP-OES/MS, XRD, SEM) to track recovery and impurity partitioning.
• Clear communicator, able to work on-site with pilot and commercial teams.

Responsibilities

• Own the design and commissioning of the downstream gas-phase separations train.
• Scale reactor from pilot to multi-zone commercial system with heat integration.
• Specify materials of construction, interlocks, and long-lead reactor equipment.
• Manage gas streams end-to-end: reactor interfaces, transport, venting, scrubbing, and recycle.
• Collaborate with vendors and on-site teams during pilot campaigns and commissioning.

Skills

Process scale-up

Gas-phase separations

High-temperature reactor

Corrosive gas service

Materials selection

Condenser/desublimation

Mass & energy balances

Analytical methods (ICP-OES/MS, XRD,  

On-site commissioning

Vendor collaboration

Job description

You will own the engineering scale-up of our downstream gas-phase separations train and the upstream high-temperature reactor that feeds it. The separations train is where the product slate is made: a mixed product vapor is split into discrete gallium, germanium, and silicon streams via staged condensation, desublimation, and scrubbing. The reactor runs hot and in corrosive gas service. Both have to scale from our current multi-kilogram pilot to a 100 ton-per-day facility over the next two and a half years. This role exists because the unit operations we need have not been built at commercial scale in the United States in over thirty years. You will design them from primary pilot data. The chemistry is metallurgical, but the engineering rides on top of universal physical principles: hot acid-gas service, multi-component condensation, scrubbing, and recycle loop design. We are explicitly open to candidates from refining, petrochemicals, sulfur recovery, and specialty gas processing whose backgrounds map onto these unit operations, alongside candidates from extractive metallurgy. This is not a QA, QC, validation, or plant-operations role. We are not hiring someone to maintain a process. We are hiring someone to design one that does not yet exist. This is not a desk role. You will be in the pilot bay running campaigns, in the design tools sizing equipment, on calls with vendors specifying alloys and internals, and on site for commissioning. What You Will Own Gas-phase separations train. Design and commission the downstream train that splits a mixed product vapor into discrete gallium, germanium, and silicon streams via staged condensation, desublimation, and scrubbing. Own the thermal profile, vessel internals, materials of construction, sequencing logic, and the close-cut separations that determine final product purity. This is where the product slate is made. Reactor scale-up. Take our current single-zone pilot reactor to a multi-zone commercial system that feeds the separations train at spec. Own residence time, gas-solid contacting, freeboard, refractory and alloy selection, and heat integration. Specify and procure the long-lead reactor itself. Hot corrosive gas management. Own the gas stream end to end: reactor offtake, transport lines between unit operations, pressure balance, vent and scrub systems, and the recycle loop that closes the reagent balance at commercial scale. The chemistry generalizes to acid-gas service across industries, including HCl, SO₂, H₂S, and NH₃ environments. This is the most under-engineered system in pyrometallurgical scale-up and the one most likely to determine whether the facility runs. Mass and energy balances, P&IDs, and equipment specifications across the full refinery. Support AACE Class 3 cost estimation as we move into the commercial design phase. Bench and pilot experiments to close the engineering uncertainties that block scale-up. Separation efficiency at each stage, fouling and plugging, alloy and refractory compatibility at temperature, dust carryover, salt deposition. Process safety and commissioning outputs. Author the interlocks, ventilation logic, leak detection, scrubbing systems, SOPs, and commissioning protocols that fall out of pilot campaigns. You will not be inheriting a QA function. You will be authoring one.

REQUIRED SKILLS AND EXPERIENCE

• 5+ years of process engineering experience in one or more of the following: gas separations or specialty gas processing; oil and gas refining; petrochemicals; sulfur recovery, amine treating, or other acid-gas processing; pyrometallurgy or extractive metallurgy; or specialty chemicals in corrosive service.
• You have personally taken at least one condenser train, separations system, or reactor from bench or pilot through fabrication and commissioning. You can name the unit, the throughput, and what broke during startup.
• Strong working knowledge of hot corrosive gas service. Examples: HCl, SO₂, H₂S, NH₃, chlorides, or analogous acid-gas environments. You understand dew points, salt deposition, materials of construction, and corrosion mechanisms.
• Materials selection for corrosive service: nickel and high-nickel alloys (Inconel, Hastelloy, Monel), refractory linings, quartz and borosilicate, ceramic-lined transport, and sour-service-grade carbon steels where appropriate.
• Hands‑on work on unconventional or solids‑bearing feedstocks (coal ash, slag, tailings, ores, heavy residuals, or similar) is a strong plus.
• Direct experience designing, scaling, or operating condensation, desublimation, or distillation trains and high‑temperature reactors. Adjacent lineages include titanium, silicon, zirconium, polysilicon (TCS, SiCl₄), VCM/EDC, sulfur recovery, and crude distillation overhead service.
• Strong process modeling. Mass and energy balances, gas‑solid kinetics, condensation and desublimation thermodynamics, multi‑component VLE. Aspen Plus, HSC, FactSage, or equivalent.
• Hands‑on with analytical methods (ICP‑OES/MS, XRD, SEM) for tracking recovery, purity, and impurity partitioning across the process.
• Direct communicator. You write clearly, push back when something is wrong, and do not hide behind hedges or buzzwords. Excited to be on site at our pilot and at the commercial facility, in person with the team.