Thermal Mechanical Engineer

ETCH, Inc; Baltimore (MD); On-site; USD 90,000 - 120,000; Full time

Job summary

ETCH, Inc is seeking a Thermal Mechanical Engineer in Baltimore, MD to lead the design and development of advanced reactor systems. The successful candidate will focus on optimizing reactor bundles and ensuring system efficiency and safety while transitioning from pilot to commercial scale.

The ideal applicant will have a Bachelor’s or Master’s degree in Mechanical Engineering and over 5 years of experience with high-temperature systems and reactor design. Knowledge of CAD tools and relevant materials is essential.

Compensation will be commensurate with experience, and ETCH is committed to equal opportunity for all employees.

Qualifications

• 5+ years of experience in high-temperature systems and reactor design.
• Experience with chemical plants, hydrogen systems, or pyrolysis is preferred.
• Strong fundamentals in heat transfer, fluid mechanics, and structural mechanics.

Responsibilities

• Lead mechanical design and development of advanced reactor systems.
• Conduct thermal modeling and heat transfer analysis.
• Support transition from pilot to commercial-scale systems.

Skills

High-temperature systems

Reactor design / process equipment

Thermal systems engineering

Heat transfer

Fluid mechanics

Structural mechanics

Education

Bachelor’s or Master’s degree in Mechanical Engineering or related field

Tools

CAD tools (SolidWorks, Inventor, or similar)

High-temperature alloys

Pressure systems and piping design codes (ASME preferred)

Job description

Thermal Mechanical Engineer – Job Description

ETCH is a startup commercializing a radically new and efficient decarbonization technology for the simultaneous greenhouse gas‑free production of hydrogen and solid carbon from natural gas.

Primary duties include leading the design and development of advanced reactor systems and supporting infrastructure. This role will be central to scaling from pilot to commercial systems, with a strong emphasis on reactor bundles, high‑temperature design, and balance‑of‑plant (BOP) integration. Focus will be on design, improving performance and efficiency, and safety of the processes all while driving continuous improvements and innovations.

Responsibilities

Other duties include:

Reactor & Core System Design

• Design and optimize annulus reactor bundles, including thermal uniformity, flow distribution, and mechanical integrity
• Develop detailed mechanical designs for pilot reactor modifications and scale‑up to 5 MTPD (metric tons per day) reactor systems
• Perform thermal and structural calculations for high‑temperature operation (≥1000 deg C environments)
• Evaluate materials of construction considering creep, thermal expansion, and chemical compatibility

Structural & Mechanical Systems

• Design structural supports for reactor systems, accounting for thermal expansion, vibration, and load conditions
• Ensure mechanical robustness and maintainability of reactor assemblies
• Develop expansion joints, supports, and interfaces between hot and cold sections

Balance of Plant (BOP) & Layout

• Lead mechanical design and layout for balance‑of‑plant systems, including:
• Piping systems
• Valves and flow control
• Develop plant layout and equipment arrangement for pilot and commercial facilities
• Ensure proper integration between reactor core and BOP systems

Engineering Analysis & Optimization

• Conduct thermal modeling (CFD/FEA preferred) and heat transfer analysis
• Perform stress analysis and lifecycle evaluation of critical components
• Support optimization of system efficiency, uptime, and reliability

Execution & Scale‑Up

• Support transition from pilot to commercial‑scale systems
• Work closely with fabrication teams, vendors, and operations
• Participate in installation, commissioning, and troubleshooting

Qualifications

• Education: Bachelor’s or Master’s degree in Mechanical Engineering or related field
• 5+ years of experience in: High‑temperature systems, Reactor design / process equipment, Thermal systems engineering
• Experience with chemical plants, hydrogen systems, pyrolysis, or similar is highly preferred
• Strong fundamentals in: Heat transfer, Fluid mechanics, Structural mechanics
• Experience with:
  • CAD tools (SolidWorks, Inventor, or similar)
  • High‑temperature alloys, ceramics, and refractory materials
  • Pressure systems and piping design codes (ASME preferred)

Preferred Attributes

• Experience designing modular or bundled reactor systems
• Familiarity with scale‑up challenges (pilot to commercial)
• Hands‑on mindset with ability to work in fast‑paced startup environments
• Strong problem‑solving and ownership attitude

An ability to work independently as well as in a team environment toward timely execution of goals is required.

ETCH is committed to equal opportunity for its employees. To that end, ETCH does not discriminate on the basis of sex, gender, marital status, pregnancy, race, color, ethnicity, national origin, age, disability, religion, sexual orientation, gender identity or expression, veteran status or other legally protected characteristic. ETCH is committed to providing qualified individuals access to all employment programs, benefits and activities on the basis of demonstrated ability, performance and merit without regard to personal factors that are irrelevant to the program involved.

Compensation commensurate with relevant experience.