Process Engineer

Insight Global; San Leandro (CA); On-site; USD 180,000 - 260,000; Full time

Job summary

Insight Global seeks a seasoned process engineer to lead the scale-up of a gas-phase separations train and upstream high-temperature reactor. You will design and commission units from bench data through pilot campaigns to commercial scale.

On-site work in the pilot bay, sizing tools, vendor coordination for alloys and internals, and commissioning at the full-scale facility are expected. Strong corrosion-resistance, materials selection, and safety expertise are essential.

Qualifications

• 5+ years of process engineering experience in gas separations or specialty gas processing, oil and gas refining, petrochemicals, sulfur recovery, amine treating, or related corrosive service.
• You have personally taken at least one condenser train, separations system, or reactor from bench or pilot through fabrication and commissioning.
• Strong working knowledge of hot corrosive gas service and materials selection (nickel/high-nickel alloys).
• Hands-on with unusual feeds (coal ash, slag, tailings, ores) is a strong plus.
• Direct experience designing/scaling condensation, desublimation, or distillation trains and high-temp reactors.
• Proficiency with mass/energy balances and multi-component thermodynamics; Aspen/HSC/FactSage.

Responsibilities

• Own gas-phase separations train design and commissioning from pilot to commercial scale.
• Scale up reactor to multi-zone system; own residence time, gas-solid contacting, heat integration.
• Manage hot corrosive gas handling end-to-end (offtake, lines, vent, scrub) and safety interlocks.
• Develop P&IDs, mass/energy balances, equipment specs; support cost estimation.
• Draft commissioning protocols and process safety documentation.
• Collaborate with vendors on alloys and internals.

Skills

Process engineering

Gas separations

Acid-gas processing

Petrochemicals

Sulfur recovery

Amine treating

Pyrometallurgy

Corrosive service

Aspen Plus

HSC

FactSage

ICP-OES/MS

XRD

SEM

Tools

Aspen Plus

HSC

FactSage

ICP-OES/MS

XRD

SEM

Job description

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.

We are a company committed to creating diverse and inclusive environments where people can bring their full, authentic selves to work every day. We are an equal opportunity/affirmative action employer that believes everyone matters. Qualified candidates will receive consideration for employment regardless of their race, color, ethnicity, religion, sex (including pregnancy), sexual orientation, gender identity and expression, marital status, national origin, ancestry, genetic factors, age, disability, protected veteran status, military or uniformed service member status, or any other status or characteristic protected by applicable laws, regulations, and ordinances. If you need assistance and/or a reasonable accommodation due to a disability during the application or recruiting process, please send a request to [e-mail] learn more about how we collect, keep, and process your private information, please review Insight Global's Workforce Privacy Policy: https://insightglobal.com/workforce-privacy-policy/.

Skills and Requirements

• 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.
• Working knowledge of the process safety and integrity code stack a scale-up engineer accumulates over a career: OSHA PSM, NFPA 55, EPA RMP, API RP 571 (damage mechanisms), API 521, and NACE/AMPP standards (including MR0175 for sour service) where applicable.
• Familiarity with coal ash, slag, or tailings valorization, or with SCM and ASTM C618.
• SBIR Phase II or other federal contracting exposure.
• Commissioning experience on a greenfield pyrometallurgical, petrochemical, or specialty chemicals facility.
• Refinery crude unit, sulfur recovery, or amine treating experience translated to first-of-kind metallurgical scale-up.