Senior Process Modeler: Digital Twins & Scale-Up

MonoSol; Chicago, Northern (IL, KY); Hybrid; USD 130,000 - 155,000; Full time

Benefits offered by this job

Yearly incentive bonus

Profit sharing

Medical insurance

Dental insurance

Vision insurance

401k

PTO

Job summary

MonoSol is seeking an experienced process scientist/engineer to accelerate scale-up via first-principles modeling and mechanistic simulations. Build and validate models across R&D and manufacturing, linking physics to data-driven insights.

You will develop hybrid models, contribute to digital twins, and help shape modeling practices across the organization while partnering with process engineers, R&D, and data science teams.

Qualifications

• 5+ years applying process modeling, simulation, or computational engineering to real-world problems.
• Track record of building mechanistic or first-principles models that informed scale-up decisions, process design, or operational improvements.
• Experience bridging pilot-scale and manufacturing-scale operations, with an understanding of how process physics changes across scales.
• Strong ability to translate complex simulation results into clear engineering recommendations.

Responsibilities

• Develop and validate first-principles and mechanistic models for key unit operations and process systems.
• Build process flowsheet models using tools like Aspen Plus to simulate end-to-end behavior.
• Lead scale-up and process transfer from pilot to manufacturing, identifying risks and operating windows.
• Develop hybrid models that combine physics-based and data-driven approaches.
• Create visualizations and technical narratives for cross-functional teams and leadership.

Skills

First-principles modeling

Mechanistic modeling

Process modeling

Hybrid/digital twin concepts

Python

CFD

DOE

Data-driven modeling

Git

Education

Bachelor's degree in Chemical Engineering or related field

Master's or PhD preferred

Tools

Aspen Plus

Aspen HYSYS

gPROMS

ANSYS Fluent

COMSOL Multiphysics

Star-CCM+

Job description

MonoSol is seeking an experienced process scientist/engineer to accelerate scale-up via first-principles modeling and mechanistic simulations. Build and validate models across R&D and manufacturing, linking physics to data-driven insights.

You will develop hybrid models, contribute to digital twins, and help shape modeling practices across the organization while partnering with process engineers, R&D, and data science teams.