Sr. Development Engineer

Airco; Philadelphia (Philadelphia County); On-site; USD 120,000 - 180,000; Full time

Benefits offered by this job

Health insurance (Day 1)

Dental and vision coverage

401(k) with company match

HSA and FSA accounts

Short-Term Disability

Paid time off including holidays and S

Paid family leave

Weekly catered lunch

Job summary

AIRCO is a world leader in carbon conversion technology, delivering SAF from CO2 and hydrogen. We seek a researcher to develop first-principles process simulations and scale-up strategies for challenging systems.

You will convert lab results into engineering design information, guide pilot campaigns, and work with teams from development through commercial deployment. A PhD or MS in Chemical/Mechanical Eng and strong modeling skills are required.

Qualifications

• MS or PhD in Chemical Engineering, Mechanical Engineering, or closely related discipline.
• Significant experience in process development, process modeling, simulation, and scale-up engineering.
• Strong grounding in thermodynamics, reaction engineering, and separation fundamentals.
• Ability to analyze large datasets and extract mechanistic insight from data.
• Experience with first-principles or mechanistic models for chemical reaction and separation systems.

Responsibilities

• 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 and support scale-up decisions.
• Convert laboratory and pilot-scale results into Engineering Design Information and design inputs.
• Lead experimental strategies and pilot campaigns to validate models and reduce risk.
• Collaborate with cross-functional teams to advance technology from development to commercial deployment.

Skills

Process development

Process modeling

Scale-up engineering

Data analysis

First-principles modeling

Education

MS/PhD in Chemical or Mechanical Eng

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 - In addition to standard medical and dental benefits, that kick in Day 1, AIRCO is:

• 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:

• 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

• Access company-sponsored HSA and FSA accounts to save on healthcare and dependent care expenses.

Income Protection & Insurance

• Company-paid Short-Term Disability insurance.
• Optional Long-Term Disability and Life Insurance plans.
• Flexible and generous paid time off, including national holidays and sick leave.
• Paid family leave to support you during important life moments.

Retirement Savings

• Tax-deferred 401(k) plan with a 3% company match to help you invest in your future.
• Pre-tax savings on transit and parking, plus monthly company contributions.
• Ancillary benefits through Sequoia, including pet insurance and financial wellness programs.
• Employee wellness program to support your well-being.Inclusive of Wellhub & One Medical.
• Company-sponsored events and programs that promote an inclusive and values-driven workplace.
• In person weekly catered lunch every Wednesday.

At AIRCO we value employees for their unique perspectives. We are an inclusive affirmative action Equal Employment Opportunity employer. We consider applicants without regard to actual or perceived race, color, creed, religion, national origin, ancestry, citizenship status, age, sex or gender (including pregnancy, childbirth, pregnancy-related conditions, and lactation), gender identity or expression (including transgender status), sexual orientation, marital status, military service and veteran status, present or past history of intellectual, learning, mental, or physical disability (including but not limited to blindness) unless AIRCO determines that such disability prevents performance of the work involved, genetic information, or any other characteristic protected by applicable federal, state, or local laws and ordinances.

Don’t meet every single requirement? Studies have shown that women, marginalized genders and people of color are less likely to apply to jobs unless they meet every single qualification. At AIRCO we are dedicated to building a diverse, inclusive and authentic workplace, so if you’re excited about this role but your past experience doesn’t align perfectly with every qualification in the job description, we encourage you to apply anyways. You may be just the right candidate for this or other roles

This position requires access to technology, software and other information that is subject to governmental access control restrictions, due to export controls, security classification and/or designation as Controlled Unclassified Information. Employment in this position is conditioned on the candidate’s ability to obtain and maintain appropriate government authorization to access technology or information, to the extent required, including without limitation a security clearance, export license, or other documentation required to establish authorization to receive access to such items technology or information.

We may delay commencement of employment, rescind an offer of employment, terminate employment, and/or modify job responsibilities, compensation, benefits, and/or access to Company facilities and information systems, as we deem appropriate, in order to ensure compliance with applicable government access control restrictions.

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