Process Engineer (San Leandro, CA)

PHNX Materials Inc.; San Leandro (CA); On-site; USD 120,000 - 180,000; Full time

Benefits offered by this job

Opportunity to shape facility

Dynamic startup environment

Growth opportunities

Job summary

PHNX Materials Inc. is seeking a Process Engineer with deep expertise in fluid and gas-phase management, including corrosive gases and sulfur compounds, to join during our scale-up phase.

You will lead design and work cross-functionally with R&D, operations and external partners. The ideal candidate has hands-on sulfuric acid facilities experience, a strong foundation in process design, and proficiency with Aspen Plus or HYSYS to model systems, optimize performance, and ensure safe, compliant

Qualifications

• 5+ years in chemical process engineering with sulfuric acid exposure.
• Experience setting up and operating manufacturing facilities.
• Strong command of fluid dynamics, gas-phase transport, and reactive chemical systems.
• Proficiency in process simulation software and hands-on design.

Responsibilities

• Lead process design and engineering for fluid and gas-phase systems involved in ash processing and chemical recovery.
• 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.
• Model fluid and gas behavior to optimize pressure, temperature, and chemical compatibility.
• Support material selection and corrosion mitigation for piping, tanks, and equipment.
• Interface with EPC contractors and vendors on equipment design and procurement.
• Ensure safety, emissions control, and regulatory compliance for chemical handling and gas management.

Skills

Process engineering

Fluid dynamics

Gas-phase transport

Reactive systems

Aspen Plus

HYSYS

Education

Chemical Engineering degrees

Tools

Aspen Plus

HYSYS

Job description

Note: We can only hire U.S. nationals due to obligations around our funding.

About PHNX Materials:

China controls 98% of the world's gallium, 92% of germanium, and 93% of silicon. In 2024, China weaponized export restrictions on gallium and germanium, putting the vulnerability on full display. Each of these metals is a byproduct of heavy industry that no longer exists in the United States. We cannot reshore the supply chain because the underlying industries are gone.

PHNX is the Department of Energy's and Department of War's answer to closing that gap. We are a "solids refinery" turning industrial waste, primarily coal ash and zinc slag, into three product streams: critical metals for semiconductors and defense, cement replacement material for construction, and fertilizer for agriculture.

Our platform delivers a triple win: securing domestic critical mineral supply chains, helping power producers retire coal ash liabilities, and giving concrete producers a cheaper, lower-carbon alternative to cement. We support coal communities and remediate groundwater. PHNX was founded by Stanford, Tesla, and national lab alumni, backed by Trust Ventures, Overture, and KdT, and sponsored by the U.S. Department of War and the U.S. Department of Energy.

The Role:

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-functional 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.

What You Will Own:

• 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.

Who You Are:

• 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 challenges.

• Dynamic startup environment with mission-driven team and room for growth.

• The chance to revolutionize heavy industries.

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 laws.