Scale-Up Process Engineer: Pyro Metallurgy & Gas Separation

Insight Global

San Leandro (CA)

On-site

USD 180,000 - 260,000

Full time

14 days+

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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.