Sr. Development Engineer

aircompany

New Britain Township (Bucks County)

On-site

USD 140,000 - 210,000

Full time

7 days ago

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Benefits offered by this job

Health benefits

HSA/FSA

Short-Term Disability

Long-Term Disability (optional)

401(k) with match

Paid time off

Commuter benefits

Pet insurance

Job summary

AIRCO, a world leader in carbon conversion technology, seeks a senior process modeling expert to develop first-principles simulations for SAF production from CO2 and hydrogen. Translate lab results into design information, support scale-up decisions, and collaborate with teams to advance technology toward demonstration and commercialization.

Requirements include an MS or PhD in Chemical or Mechanical Engineering, strong experience in process modeling, thermodynamics, and data analysis using

Qualifications

MS or PhD in Chemical/Mechanical Engineering or related field.
Significant experience in process development, modeling, and scale-up.
Strong thermodynamics and reaction engineering background.
Ability to analyze large datasets and extract mechanistic insight.

Responsibilities

Develop and maintain first-principles process simulations for SAF production.
Apply modeling and data analytics to predict performance and guide scale-up decisions.
Translate lab and pilot results into Engineering Design Information and performance projections.
Lead experimental strategies and pilot campaigns to validate models and reduce risk.
Collaborate with cross-functional teams toward demonstration and commercialization.

Skills

Process modeling

Data analysis

Scale-up engineering

Thermodynamics

Python/MATLAB

Education

MS/PhD in Chemical or Mechanical Engineering

Tools

Aspen

MATLAB

Python

Job description

About AIRCO

AIRCO is a world leader in carbon conversion technology, paving the way to global energy security by transforming CO₂ into a valuable resource. Its proprietary AIRMADE™ Technology is an adaptable platform that allows any industry to efficiently produce high-demand, fully-formulated synthetic fuels from waste CO₂ and hydrogen.

The company has commercial partnerships with airlines including JetBlue and Virgin Atlantic, amongst others, and has been awarded multiple government contracts, including with NASA and the United States Department of Defense's Defense Innovation Unit. The company has received industry recognition through awards such as Time Best Inventions, Inc. Best in Business, Fast Company World Changing Ideas, and the XPrize for Carbon Removal.

AIRCO's many accolades include winning the prestigious Green Chemistry Challenge Award from the Environmental Protection Agency in October 2023, an award given to organizations that reinvent processes to reduce the generation of hazardous substances and byproducts. AIRCO was also declared a winner for the World Economic Forum UpLink Sustainable Aviation Challenge, which accelerates the development of promising technology pathways that enable widespread uptake of SAF.

What you get to do

Develop and maintain first-principles process simulations and mechanistic models for reaction, separation, and integrated SAF production systems.
Apply modeling, simulation, and data analytics to predict performance, support scale-up decisions, optimize process design, and reduce commercialization risk.
Convert laboratory and pilot-scale results into Engineering Design Information (EDI), process design inputs, and technology performance projections.
Lead the development of experimental strategies and pilot campaigns required to validate models, resolve technical uncertainties, and strengthen scale-up confidence.
Partner with cross-functional teams to advance technology from development through demonstration and commercial deployment, while identifying opportunities for innovation and process improvement.

What you bring to AIRCO

M.S. or Ph.D. in Chemical Engineering, Mechanical Engineering, or a closely related discipline
Significant experience in process development, process modeling, simulation, and scale-up engineering within chemical process industries.
Strong grounding in thermodynamics, reaction engineering, and separation fundamentals
Demonstrated ability to analyze large datasets and extract mechanistic insight, not just empirical fits
Advanced experience with numerical tools, simulation software, or data analysis platforms (e.g., Aspen, MATLAB, Python, similar)
Demonstrated experience developing first-principles, mechanistic, or hybrid process models for chemical reaction and separation systems.
Experience applying simulation and modeling tools to technology scale-up, process design, and commercialization decisions.
Ability to bridge experimental observations and engineering models to generate predictive process understanding.
Proven ability to use engineering fundamentals, experimental data, and simulation tools to diagnose process behavior and resolve technical challenges.
Experience in fuels, petrochemicals, refining, catalysis, or sustainable energy technologies
Familiarity with scale-up challenges, process modeling, and commercialization workflows
Experience supporting or delivering EDI / FEL engineering packages

Working at AIRCO

A team of engineers, scientists, operators, builders, and innovators working on hard problems with tangible impact.
A company building and deploying real systems for fuel and chemical production in real-world conditions.
A hands-on environment where ownership is clear, decisions stay close to the work, and teams move with trust, discipline, and speed.
Driven by work that matters, with a culture grounded in safety, teamwork, transparency, purpose, agility, ambition, and creativity.

We also provide

Comprehensive Health Benefits

Full coverage for employee base premiums on health, dental, and vision insurance.
70% coverage for spouse and dependent base premiums.
Choose between base plans or enhanced options to fit your needs.

Health Savings & Flexibility