Senior Process Engineer

Oxylus Energy; Branford (CT); On-site; USD 115,000 - 135,000; Full time

Benefits offered by this job

Competitive salary

Medical, dental, and vision coverage

Paid sick days and vacation

401k match

A diverse and inclusive work enviro n.

Job summary

Oxylus Energy is seeking a Senior Process Engineer to lead the process design for integrated electrolyzer and downstream catalytic systems in Branford, CT. You will own balance‑of‑plant design, scale‑up strategies, and hazardous‑gas safety analyses while collaborating with chemists and mechanical engineers.

You will design high‑pressure reactors, guide process hazard analyses, mentor engineers, and drive techno‑economic optimization toward commercial scale, with relocation to the

Qualifications

• Bachelor's degree in Chemical Engineering or related field and one of the following experience tracks.
• Proven track record leading process design for high‑pressure reactor systems.
• Strong expertise in kinetics, heat integration, mass and energy balances.
• Experience with process hazard analyses for pressurized, flammable, or toxic gas systems.
• Proficiency with process simulation tools such as Aspen Plus or Aspen HYSYS.

Responsibilities

• Define and own the process architecture for integrated electrolyzer and thermal catalytic systems from lab scale through pilot plant design.
• Own the balance of plant design including CO₂ supply, gas handling, purification, compression, water management, heat integration, and product handling.
• Lead integration of electrolyzer with downstream catalytic processes and optimize stream matching and recycle strategies.
• Lead design, build, and operation of high‑pressure catalytic reactor systems and evaluate catalyst activity, selectivity, and stability.
• Develop reactor designs and models using kinetics and energy balances to size equipment and set operating conditions.
• Mentor junior engineers and present plans and results to leadership and partners.

Skills

Process design

Reactor operation

Mentoring engineers

Project leadership

Education

Chemical Engineering degree

B.S. with 7+ years

M.S. with 5+ years

Ph.D. with 2+ years

Tools

Aspen Plus

Aspen HYSYS

ASME Code

Job description

Senior Process Engineer

On-site, Branford, CT (must be willing to relocate to the Bridgeport/Stamford area within one year of the start date)

About Oxylus Energy

Oxylus Energy is a climate-tech company building solutions that can scale. Our breakthrough electrochemical technology converts carbon dioxide into low-carbon fuels and chemicals, reducing the world's dependence on fossil fuels. We are a team of scientists, engineers, and problem solvers working to make that future real.

Job brief

As Senior Process Engineer, you will lead the process design of Oxylus' integrated systems. You will own the balance of plant for our CO₂ electrolyzers and set the strategy for integrating our electrolyzer technology with downstream thermal heterogeneous catalysis, turning CO-rich product streams into feedstocks for processes such as Fischer-Tropsch or methanol synthesis. You will define the process architecture that takes us from lab-scale demonstrations to pilot and, eventually, commercial plants.

You will remain hands-on, designing, building, and operating high-pressure reactor systems and pilot equipment. You will also lead process hazard analyses, guide scale-up decisions, and mentor other engineers. Because our systems handle pressurized and hazardous gases, including CO and H₂, safe design and operation are central to this role. You will work closely with our electrochemists, materials scientists, mechanical and controls engineers, and leadership, and represent our process technology with partners.

What You Will Do

• Define and own the process architecture for integrated electrolyzer and thermal catalytic systems, from lab scale through pilot plant design.

• Own the design of the balance of plant, including CO₂ supply and conditioning, gas separation and purification, compression, water management, heat integration, and product handling.

• Lead the integration of our electrolyzer with downstream heterogeneous catalytic processes, including stream matching, recycle strategies, and overall process efficiency.

• Lead the design, build, and operation of high-pressure catalytic reactor systems, and direct catalyst evaluation for activity, selectivity, and stability.

• Develop reactor designs and process models, using kinetics, mass and energy balances, and heat-transfer analysis to size equipment and set operating conditions.

• Specify pumps, compressors, heat exchangers, separators, and other process equipment, and manage relationships with vendors, fabricators, and engineering firms.

• Own PFDs, P&IDs, heat and material balances, and equipment datasheets for integrated systems.

• Lead process hazard analyses, such as HAZOP, and make sure designs comply with applicable codes and standards for high-pressure and hazardous-gas systems.

• Drive techno-economic analysis and scale-up planning, and identify the process changes with the greatest impact on cost and performance.

• Mentor junior engineers, review their designs, and help grow the process engineering function.

• Present technical plans, risks, and results to leadership, partners, and funding agencies, and contribute to grant proposals and reports.

Who You Are

• A degree in Chemical Engineering or a related field, with one of the following:

  • B.S. with 7+ years of relevant experience.

  • M.S. with 5+ years of relevant experience.

  • Ph.D. with 2+ years of relevant experience.

• A track record of leading process design for high-pressure reactor systems from concept through commissioning and operation.

• Deep experience with heterogeneous catalysis, including catalyst testing and reactor performance analysis.

• Strong expertise in reactor design, kinetics, heat integration, and mass and energy balances.

• Experience specifying, operating, and troubleshooting pumps and compressors.

• Familiarity with pressure equipment codes such as ASME Boiler and Pressure Vessel Code Section VIII and ASME B31.3.

• Experience leading process hazard analyses for pressurized, flammable, or toxic gas systems.

• Proficiency with process simulation tools such as Aspen Plus or Aspen HYSYS.

• Experience mentoring engineers or leading small technical teams.

• Highly attentive to detail, with strong problem-solving and organizational skills.

• Excellent written, verbal, and presentation skills.

Nice to Have

• Direct experience with syngas conversion, such as Fischer-Tropsch or methanol synthesis.

• Experience scaling processes from lab to pilot or demonstration plants.

• Experience with gas separation technologies, such as pressure swing adsorption (PSA) or membrane separation.

• Experience with techno-economic analysis or life-cycle assessment.

• Familiarity with electrolyzers or other electrochemical systems.

Salary

• USD 115,000 - 135,000 per year base salary commensurate with experience, education, and skills.

Benefits

• Competitive salary

• Medical, dental, and vision coverage

• Paid sick days and vacation

• 401k match

• A diverse and inclusive work environment

If you need an accommodation during the application process, reach out to [e-mail].

Equal opportunity

We believe the distinct contributions of each person fuel our success. To keep our products and culture inclusive of all viewpoints and experiences, Oxylus Energy does not discriminate on the basis of race, color, religion, sex, national origin, gender identity or expression, sexual orientation, age, marital status, veteran status, disability, or any other characteristic protected by law.