Senior Process Engineer — Rotary Kilns & High-Temperature Reactors

Raven-Flint Nuclear Corporation; Idaho Falls, Northern (ID, KY); Hybrid; USD 140,000 - 190,000; Full time

Benefits offered by this job

Equity / stock options

Medical health insurance

Unlimited paid time off and holidays

Relocation assistance to Idaho Falls

Job summary

Raven-Flint Nuclear Corporation in Idaho Falls seeks a Senior Process Engineer to own a high-temperature rotary reactor system, including the design basis, thermal profile, residence-time distribution, and safety case.

You will work with our chemistry team to translate lab data into a defensible reactor design and oversee FEED, HAZOPs, and EPC interfaces as the technical owner.

Qualifications

• Experience with rotary reactor design and high-temperature service.
• Strong background in heat transfer, residence-time, and thermal profiling.
• Proven FEED to detailed design ownership and P&IDs experience.
• Experience with process safety management and MOC processes.
• Ability to work with vendors and scale-up rotary equipment

Responsibilities

• Own reactor design basis, thermal models, and material balances.
• Set temperature profile, fill fraction, slope, and speed for scale-up.
• Specify heating method and material choices for controlled atmospheres.
• Define solids feed/discharge and off-gas handling scope with vendors.
• Develop PFDs and P&IDs through concept select, FEED, and HAZOP.
• Define materials, corrosion, and containment requirements with engineers.
• Produce process datasheets and support long-lead equipment orders.
• Lead HAZID/HAZOP participation and close-out for the system.
• Serve as technical owner through EPC oversight and design reviews.

Skills

Rotary kiln design

Heat transfer modeling

FEED and P&ID experience

Process Safety Management

Vendor-facing scale-up

Regulated-material background

Education

B.S. in Chemical, Mechanical, or Materials Engineering

Advanced degree welcomed

Job description

Senior Process Engineer — Rotary Kilns & High-Temperature Reactors

Process Engineering · Idaho Falls, ID · Full-time

About Raven-Flint

Raven-Flint Nuclear Corporation is building the first uranium conversion plant designed from the ground up to operate without elemental fluorine (F2). Conversion is the critical, under-supplied step that turns uranium oxide into the uranium hexafluoride (UF6) feedstock the enrichment industry depends on — and we intend to rebuild that capability on U.S. soil with a process that is fundamentally safer and simpler.We are headquartered in Idaho Falls, Idaho, and we scale in three deliberate stages. Match, our bench-scale proof of the process chemistry, is due in 2026. Torch, our pilot plant, comes online in Idaho in mid-2028 and will convert 500 metric tons of uranium per year into UF6. Forge, our full commercial plant, follows by 2030.We are well funded, the roadmap is clear, and our only real constraint is time. We believe hardware testing — not paperwork — is the truest measure of progress, and we are moving fast to take our chemistry out of the lab and into a running plant. This is a once-in-a-generation chance to rebuild a critical piece of the nuclear fuel cycle on American soil — and if you want to see your designs cut metal, get built, and run, there is no better place to be.

The Role

You will own a high-temperature rotary reaction system outright: the design basis, the thermal profile and residence-time distribution, the heat and material balances, the PFDs and P&IDs, and the safety case. Heat transfer, solids conveying and hold-up, agglomeration and ring formation, refractory and alloy selection, end-seal integrity in a controlled atmosphere, and off-gas handling are yours to get right — and most of them are decided once, at the vendor's shop, and lived with for the life of the plant.This is a scarce specialty and we are treating it as one. You will work directly with our chemistry team to carry laboratory data into a defensible reactor design, and you keep the system after FEED — as its named owner overseeing our EPC's detailed design, sitting in the HAZOPs, and approving what gets built.We run a fast-paced front end with a small senior team, backed by an AI documentation pipeline that absorbs the volume work so your hours go to engineering judgment instead of formatting.

What you'll do

• - Own the reactor design basis, thermal and residence-time models, and heat and material balances
• - Set the temperature profile, fill fraction, slope, and speed basis, and defend the scale-up argument
• - Specify heating method, refractory and alloy selection, and end-seal arrangement for controlled-atmosphere service
• - Define solids feed, discharge, and off-gas handling scope with mechanical and vendors
• - Develop and defend the system's PFDs and P&IDs through concept select, FEED, and HAZOP
• - Set materials, corrosion, and containment requirements with the materials and mechanical engineers
• - Produce process datasheets and support long-lead equipment requisitions
• - Lead HAZID/HAZOP participation and close-out for your system
• - Carry the system into EPC oversight as its named technical owner — design reviews, technical bid evaluations, MOC authority

What you bring

• - B.S. in Chemical, Mechanical, or Materials Engineering or equivalent; advanced degree welcome
• - 8+ years process engineering, or 6+ with a graduate degree in a related field, including direct rotary kiln, calciner, or high-temperature furnace design work
• - Demonstrated rotary-reactor engineering: thermal profile and heat-transfer modeling, residence-time and fill-fraction basis, scale-up from bench or pilot data
• - Working knowledge of refractory, alloy, and seal selection for high-temperature service
• - Solids handling design: feed and discharge systems, agglomeration and ring mitigation, off-gas dust control
• - Track record owning a process system through FEED or detailed design (basis → P&IDs → HAZOP)
• - Experience in Process Safety Management (PSM) — PHA participation, MOC, and safeguarding documentation
• - Ability to access export-controlled technology: U.S. citizen or lawful permanent resident, or eligibility for required authorizations
• - Preferred: kilns or calciners in corrosive or controlled-atmosphere service
• - Preferred: vendor-facing scale-up experience with rotary equipment suppliers
• - Preferred: nuclear fuel cycle, uranium processing, or other regulated-material background
• Equity / stock options
• Medical health insurance
• Unlimited paid time off and holidays
• Relocation assistance to the Idaho Falls area