Process Engineer - Fluid & Gas-Phase Systems

PHNX Materials; San Francisco (CA); On-site; USD 130,000 - 190,000; Full time

Benefits offered by this job

Dynamic startup environment

Room for growth

Impactful environmental mission

Job summary

PHNX Materials is seeking a Process Engineer to join during our scale-up phase. The role focuses on fluid and gas‑phase management, particularly with corrosive gases and sulfur compounds, interfacing with R&D, operations, and external partners.

The ideal candidate has hands‑on experience with sulfuric acid facilities and strong skills in process design, fluid dynamics, and material compatibility to deploy novel chemical systems at scale.

Qualifications

• 5+ years of chemical process engineering experience with direct exposure to sulfuric acid or similar facilities.
• Experience with setting up and operating manufacturing facilities.
• Strong command of fluid dynamics, gas-phase transport, and reactive chemical systems.
• Proficiency in process simulation software (e.g., Aspen Plus, HYSYS) and hands‑on process design experience.

Responsibilities

• Lead process design and engineering for fluid and gas‑phase systems involved in ash processing and chemical recovery, including sulfuric acid and other volatile or corrosive compounds.
• Develop and refine PFDs, P&IDs, and mass/energy balances for pilot and full‑scale systems.
• Design and specify unit operations such as scrubbers, absorbers, degassers, pressure vessels, and neutralizers.
• Collaborate with R&D to translate lab results into scalable engineering solutions and troubleshoot performance.

Skills

Chemical process engineering

Fluid dynamics

Process design

Aspen Plus

HYSYS

Education

Chemical Engineering degree (Bachelors/Master’s/PhD)

Tools

Aspen Plus

HYSYS

Job description

About PHNX Materials

PHNX Materials addresses the dwindling supply of fly ash—a key ingredient in concrete—by refining 23 billion tons of landfilled coal ash into ASTM-grade fly ash and critical metals. Our cost-effective, scalable technology delivers a triple win: helping utilities manage coal ash— a waste stream four times larger than plastic—providing concrete companies a cheaper, greener alternative to cement, and supplying industries with domestic sources of aluminum, rare-earth elements and titanium. Founded by Stanford and Tesla alumni, PHNX is on a mission to mine this abundant domestic natural resource.

About PHNX Materials

PHNX Materials addresses the dwindling supply of fly ash—a key ingredient in concrete—by refining 23 billion tons of landfilled coal ash into ASTM-grade fly ash and critical metals. Our cost-effective, scalable technology delivers a triple win: helping utilities manage coal ash— a waste stream four times larger than plastic—providing concrete companies a cheaper, greener alternative to cement, and supplying industries with domestic sources of aluminum, rare-earth elements and titanium. Founded by Stanford and Tesla alumni, PHNX is on a mission to mine this abundant domestic natural resource.

Position Overview

We are seeking a Process Engineer with deep expertise in fluid and gas-phase management, particularly involving corrosive gases, and sulfur compounds, to join our team as a critical technical contributor during our scale-up phase. This role will work cross-functionally with R&D, operations, and external engineering partners.

The ideal candidate brings hands‑on experience from sulfuric acid facilities and a strong foundation in process design, fluid dynamics, chemical compatibility, and material selection. This is a unique opportunity to shape and deploy novel chemical systems at scale.

Key Responsibilities

• Lead process design and engineering for fluid and gas‑phase systems involved in ash processing and chemical recovery, including sulfuric acid and other volatile or corrosive compounds.
• Develop and refine process flow diagrams (PFDs), piping and instrumentation diagrams (P&IDs), and mass and energy balances for both pilot and full‑scale systems.
• Design and specify key unit operations such as scrubbers, absorbers, degassers, pressure vessels, and neutralizers.
• Collaborate closely with the R&D team to translate lab‑scale results into scalable, field‑ready engineering solutions, including troubleshooting performance and modifying designs as needed.
• Model fluid and gas behavior across complex chemical systems, optimizing for pressure, temperature, and chemical compatibility.
• Support material selection and corrosion mitigation strategies for process piping, tanks, and equipment.
• Interface with EPC contractors and vendors on equipment design, process integration, and procurement decisions.
• Ensure system safety, emissions control, and compliance with environmental regulations related to chemical handling and gas management.

Qualifications

• 5+ years of experience in chemical process engineering with direct exposure to sulfuric acid or similar chemical facilities.
• Ideally experience with setting up and operating manufacturing facilities.
• Strong command of fluid dynamics, gas-phase transport, and reactive chemical systems.
• Proficiency in process simulation software (e.g., Aspen Plus, HYSYS) and hands‑on experience in process design.
• Experience collaborating across R&D and engineering functions to bring new technologies to life.
• Bachelor's / Master’s / PhD degree in Chemical Engineering or a related discipline.
• A commitment to safety, environmental responsibility, and engineering rigor.

What We Offer

• Opportunity to shape and build a facility tackling major environmental challenges.
• Dynamic startup environment with mission‑driven team and room for growth.
• The chance to revolutionize heavy industries.

Note: We are unable to sponsor non‑U.S. citizens at this time. We welcome applicants on OPT.

PHNX Materials is an Equal Opportunity/Affirmative Action employer. All qualified applicants will receive consideration for employment without regard to sex, gender identity, sexual orientation, race, color, religion, disability, protected Veteran status, age, or any other characteristic protected by applicable law.