Staff Process Development Engineer

Electra

Boulder (CO)

On-site

USD 135,000 - 185,000

Full time

2 days ago

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Benefits offered by this job

Health premiums covered

HSA contributions

401k matching

Job summary

Electra in Boulder, CO is seeking a Staff Process Development Engineer to lead the development, design, and scale-up of chemical and hydrometallurgical processes from bench-scale proof-of-concept through pilot and demonstration facilities.

You will partner with engineering teams to drive sound technical decisions as Electra scales toward commercial operations, with a strong emphasis on process safety and cross-functional collaboration.

Qualifications

Bachelor’s degree in chemical engineering, mining/metallurgical engineering, chemistry, or related field.
12+ years of industry experience; OR 8+ years with a Master’s; OR 5+ years with a PhD; or equivalent.
Deep experience in process design, mass/energy balances, reaction kinetics, thermodynamics, separations, and fluid flow.
Demonstrated technical leadership on complex process projects and trusted SME
Ability to influence across disciplines without formal authority and to lead safety reviews

Responsibilities

Provide technical leadership for complex process development and scale-up from laboratory to pilot and demonstration scale.
Design and guide development of chemical process systems, including mass/energy balances, P&IDs, equipment specs, fabrication, and commissioning.
Develop technical approaches for process development and scale-up using engineering principles and data.
Lead process safety activities, including HAZOPs, FMEAs, and hazard reviews.
Collaborate across mechanical, electrical, controls, and other engineering disciplines to define requirements.
Analyze experimental data and translate findings into actionable recommendations.
Lead commissioning, troubleshooting, and optimization of equipment and processes to improve safety and reliability.

Skills

Process design

Mass & energy balances

Reaction kinetics

Thermodynamics

Safety leadership

Data analysis

Modeling

Laboratory testing

Education

Chemical engineering degree

Master’s degree preferred

PhD considered

Tools

Process simulation software

Microsoft Excel

Microsoft PowerPoint

MS Office tools

Job description

Who We Are

Electra is reinventing ironmaking from the ground up with a breakthrough electrochemical technology that produces high purity clean iron and critical co-minerals. With two operating pilots in Boulder and a new demonstration facility underway in Jefferson County, we’re on track to reach commercial scale by the end of the decade. Backed by over $300 million and strategic partnerships with global leaders across mining, steel, and big tech, momentum is on our side. Recognized by Fast Company as a Most Innovative Company and a Next Big Thing in Tech, and named one of TIME’s 100 Climate Leaders, we’re building a company shaping the future of industry. If you’re looking to make an impact and join a team that’s driven, focused, and scaling, we want to hear from you.

Who We Are

What You Will Do

The Staff Process Development Engineer will provide technical leadership for the development, design, and scale‑up of chemical and hydrometallurgical processes across a range of scales, from bench‑scale proof‑of‑concept through Electra’s pilot and demonstration facilities. This role will serve as a senior technical resource within process engineering, driving complex development efforts, shaping technical approaches, and partnering across engineering teams to support sound technical decisions as Electra advances toward commercial‑scale operations.

Responsibilities Include

Provide technical leadership for complex process development and scale‑up projects from laboratory through pilot and demonstration scale
Design and guide development of chemical process systems, including mass and energy balances, P&IDs, equipment specifications, fabrication, and commissioning
Develop technical approaches for process development and scale‑up using engineering principles, modeling, and experimental data
Lead process safety activities, including HAZOPs, FMEAs, and other hazard reviews
Partner across mechanical, electrical, controls, and other engineering disciplines to define requirements and support technical decisions
Analyze complex experimental and process data and translate findings into recommendations that guide engineering and business decisions
Lead commissioning, troubleshooting, and optimization of equipment and process systems to improve safety, reliability, and performance
Advance process development and engineering practices through documentation, practical standards, and knowledge sharing
Serve as a trusted technical resource and mentor, providing guidance on complex process engineering challenges
Maintain a safe working environment and lead safety assessments for new equipment, processes, and operations
Read, understand, and comply with all workplace health and safety policies, safe work practices, and company policies and procedures
Perform other duties as assigned

What We Need You To Bring To The Team

Bachelor’s degree in chemical engineering, mining/metallurgical engineering, chemistry, or a related field
12+ years of relevant industry experience; OR 8+ years with a Master’s degree; OR 5+ years with a PhD; or equivalent experience (excludes internships, co‑ops and other school projects)
Deep experience in process design, including mass and energy balances, reaction kinetics, thermodynamics, separations, and fluid flow
Demonstrated ability to provide technical leadership on complex process engineering projects and serve as a trusted subject‑matter resource
Proven ability to influence technical decisions and collaborate effectively across engineering disciplines and functions without relying on formal authority
Demonstrated success implementing safety measures for gas‑and‑liquid‑processing systems and leading process safety reviews
Expert proficiency with process simulation software and the ability to use models to inform experimental design, predict outcomes, and guide process development and scale‑up
Strong ability to analyze complex experimental data, recognize meaningful patterns, develop technical recommendations, and communicate results clearly to both technical and non‑technical teams
Solid experience in analytical chemistry and applying it to troubleshoot complex experimental issues, evaluate alternatives, and determine appropriate technical approaches
Strong understanding of fluid power systems, including pumps, valves, and heat‑exchange equipment, and how they integrate into larger mechanical and process systems
Hands‑on experience using power tools and basic fabrication methods to build or modify custom equipment supporting testing, development, and process improvement
Experience coordinating with external vendors, providing technical guidance, tracking progress, and ensuring contracted work meets quality, schedule, and project objectives
Demonstrated ability to improve engineering practices, share knowledge, and contribute to the technical development of others
Proficient in, or able to quickly pick up, Microsoft Office applications including Word, Excel, PowerPoint, Outlook, OneDrive, and SharePoint to create clear documentation and support project needs

Compensation

The anticipated starting pay range for this position is $135,000-$185,000 and may be more or less depending upon skills, experience, and education.

Benefits For You

100% paid premiums across all medical, dental, vision, telemedicine, short‑term disability, long‑term disability, and basic life insurance plans
$1,800 in annual employer HSA contributions (health savings account)

Benefits For Your Family