Sr. Process Development Engineer - Pyrolysis Test

Charm Industrial; Fort Lupton (CO); On-site; USD 98,400 - 147,600; Full time

Benefits offered by this job

Equity ownership through stock options

100% employee healthcare premiums covered

Paid leave, including parental and medical leave

Annual professional development stipend

Job summary

Charm Industrial in Fort Lupton, Colorado is seeking a Senior Process Development Engineer to lead the development and scale-up of innovative biomass conversion processes. This role involves tackling complex process challenges and providing leadership across various teams.

The ideal candidate will have at least 7 years of experience in process engineering, a thorough understanding of heat transfer, and excellent communication skills. The company offers equity ownership, comprehensive healthcare, and an environment dedicated to meaningful impact.

Qualifications

• 7+ years of experience in process development engineering.
• Experience managing pilot-scale systems.
• Deep understanding of heat transfer and mass balances.

Responsibilities

• Lead development of next-generation biomass conversion processes.
• Own investigation of complex process performance challenges.
• Prepare and review engineering documentation including SOPs.

Skills

Process development engineering

Scale-up engineering

Troubleshooting

Chemical processes

Cross-functional project leadership

Communication skills

Education

Bachelor's degree in Chemical or Mechanical Engineering

Tools

Process Flow Diagrams (PFDs)

Piping and Instrumentation Diagrams (P&IDs)

Process Control Narratives (PCNs)

Job description

About the Role

We're looking for a Senior Process Development Engineer to join our Pyrolysis Test Engineering team. Reporting to the Director of Pyrolysis, you will lead the development and scale‑up of next‑generation biomass conversion processes from pilot testing through commercial deployment. You will define experimental strategy, drive resolution of complex scale‑up challenges, and provide technical leadership across R&D, Engineering, and Operations teams.

This role requires deep process engineering expertise, strong technical judgment, and the ability to translate ambiguous experimental findings into robust, scalable industrial processes.

Your Responsibilities

• Lead development of next‑generation Charm pyrolyzers and biomass conversion processes to maximize bio‑oil yield, product quality, reliability, and economic performance.
• Define test plans and experimental campaigns that address critical technical uncertainties and inform commercialization decisions.
• Own investigation and resolution of complex process performance, operability, and scale‑up challenges across pilot and demonstration systems.
• Develop and validate process models, material and energy balances, and engineering analyses to guide process improvements and future facility design.
• Lead interpretation and communication of experimental results to technical and non‑technical stakeholders, including recommendations for strategic development priorities.
• Prepare and review process engineering documentation including Process Flow Diagrams (PFDs), Piping and Instrumentation Diagrams (P&IDs), Process Control Narratives (PCNs), Standard Operating Procedures (SOPs), and process equipment specifications.
• Lead or facilitate process safety activities including Hazard and Operability study (HAZOP), Failure Mode and Effects Analysis (FMEA), Management of Change (MOC) reviews, and commissioning/startup readiness reviews.
• Partner closely with Mechanical, Automation, Electrical, Manufacturing, and Operations teams to ensure successful deployment and operation of new process technologies.
• Mentor junior engineers and contribute to the development of engineering standards, best practices, and technical culture across the organization.
• Support our 24/7 operations through a rotating after‑hours coverage schedule, totaling approximately 2–3 weeks per year.

You Bring

• Bachelor's degree in Chemical Engineering, Mechanical Engineering, or a related field.
• 7+ years of experience in process development engineering, or scale‑up engineering, including significant experience operating and developing pilot‑scale systems.
• Demonstrated success scaling chemical, thermochemical, energy, or industrial process technologies from pilot through commercial deployment.
• Deep understanding of heat transfer, reaction engineering, mass and energy balances, process controls, process safety, and industrial operations.
• Strong hands‑on troubleshooting skills and the ability to diagnose complex process and equipment failures in ambiguous environments.
• Experience leading cross‑functional technical projects involving multiple engineering disciplines.
• Excellent written and verbal communication skills, including the ability to influence technical direction and align diverse stakeholders.
• Strong engineering judgment and ability to balance technical rigor, operational realities, schedule, and cost.
• Excitement for scaling industrial technologies that can meaningfully impact climate change.

Bonus if you Bring

• M.S. or Ph.D. in Chemical Engineering, Mechanical Engineering, or a related field.
• Experience with pyrolysis, gasification, biomass conversion, refining, petrochemicals, renewable fuels, or other thermochemical processing technologies.
• Experience commissioning and operating industrial process systems at demonstration or commercial scale.
• Experience leading process hazard analyses and implementing process safety management programs.
• Experience managing external engineering partners, equipment vendors, or contract manufacturers.

What We Offer

• Equity ownership through stock options
• 100% employee healthcare premiums covered
• Comprehensive medical, dental, and vision coverage with multiple plan options
• Employer‑funded HSA contributions for eligible HDHP plans
• Traditional and Roth 401(k) with a 50% match on contributions up to 6%
• Paid leave, including parental and medical leave
• PPE and workwear allowances
• Annual professional development stipend
• Employee recognition programs that celebrate impactful work and team contributions
• Opportunities for internal growth, career development, and transition into climate from a range of industries and backgrounds

Visa Sponsorship Policy

Since we are a small startup, certain accommodations for visa sponsorship may not be within our capability. At this time, Charm Industrial is only sponsoring E3 and TN visas.

Our Commitment

Charm Industrial is an equal opportunity employer. We hire based on skills, experience, and passion for our mission. Climate challenges require a wide range of perspectives and expertise, and we welcome applicants from all backgrounds. We’re excited to grow our team with people who bring unique strengths and help us improve as a company.

98400 - 147600 USD a year