Senior Process Development Engineer: Scale-Up & Safety

ElectraSteel, Inc.; Boulder (CO); On-site; USD 135,000 - 185,000; Full time

Benefits offered by this job

Medical benefits

Equity

401(k) with company match

HSA

Job summary

Electra is seeking a Staff Process Development Engineer to lead development, design, and scale-up of chemical and hydrometallurgical processes from bench-scale proof-of-concept through pilot and demonstration facilities in Boulder. This role serves as a senior technical resource, driving complex development efforts and partnering across engineering teams to support commercial-scale operations.

The position emphasizes process safety, modeling, data analysis, and mentoring, with ownership of mass

Qualifications

• Bachelor’s degree in chemical engineering or related field.
• 12+ years in industry; or 8+ years with Master’s; or 5+ years with PhD; or equivalent experience.
• Deep experience in process design, mass and energy balances, kinetics, thermodynamics, separations, and fluid flow.
• Proven ability to lead complex process engineering projects and collaborate without formal authority.
• Experience with safety measures for gas- and liquid-processing systems and safety reviews.
• Proficiency in process simulation software and data-informed decision making.
• Strong communication of technical results to diverse teams.

Responsibilities

• Provide technical leadership for development and scale-up from lab to pilot and demonstration scale.
• Design chemical process systems with mass/energy balances, P&IDs, equipment specs, fabrication, and commissioning.
• Develop technical approaches using modeling and experimental data.
• Lead process safety activities, including HAZOPs and FMEAs.
• Collaborate with mechanical, electrical, controls teams to define requirements.
• Analyze data and translate findings into actionable recommendations.
• Lead commissioning, troubleshooting, and optimization of processes to improve safety and reliability.
• Mentor junior engineers and advance engineering practices and documentation.

Skills

Process design

Scale-up

HAZOPs

FMEAs

Safety reviews

Data analysis

Cross-disciplinary collaboration

Engineering leadership

Process simulation

Microsoft Office

Education

Bachelor’s degree in chemical engineering, mining/metallurgical engineering, chemistry, or related field

Tools

Process simulation software

Microsoft Office

Job description

Electra is seeking a Staff Process Development Engineer to lead development, design, and scale-up of chemical and hydrometallurgical processes from bench-scale proof-of-concept through pilot and demonstration facilities in Boulder. This role serves as a senior technical resource, driving complex development efforts and partnering across engineering teams to support commercial-scale operations.

The position emphasizes process safety, modeling, data analysis, and mentoring, with ownership of mass