Scale-Up Process Engineer: Gas-Phase Separation & Reactor Design

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

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