Senior Mechanical / Process Engineer – Pyrolysis Systems

We are seeking a Senior Mechanical/Process Engineer with expertise in pyrolysis systems to lead our technical efforts. In this role, you will be responsible for taking process concepts through to detailed, fabrication-ready designs while mentoring a growing engineering team. You will work on both batch and continuous pyrolysis systems, ensuring designs meet performance, safety, and manufacturability standards. This position offers flexibility with remote, hybrid, or on-site work arrangements and can be full-time or contract-based.

Key Responsibilities

- Develop process designs for batch and continuous pyrolysis systems, including residence time, temperature profiles, mass and energy balances, and product yield optimization.
- Design reactors and auxiliary equipment such as feed systems, cyclones, condensers, and gas handling components.
- Create detailed 3D models and comprehensive fabrication drawing packages using SolidWorks, incorporating GD&T, weld callouts, and bills of materials (BOMs).
- Perform Finite Element Analysis (FEA) and Computational Fluid Dynamics (CFD) simulations (using ANSYS or equivalent) to evaluate thermal stress, heat transfer, pressure, and gas flow in high-temperature equipment.
- Select appropriate materials for high-temperature applications, ensuring compliance with recognized codes such as ASME, ASTM, and AWS.
- Develop Piping and Instrumentation Diagrams (P&IDs), Process Flow Diagrams (PFDs), data sheets, and detailed design calculation reports.
- Define instrumentation, control systems, and safety interlocks; lead Hazard and Operability (HAZOP) studies and risk assessments.
- Support fabrication, commissioning, and scaling up processes from prototype stages to full production.

Required Qualifications

- Bachelor’s degree in Mechanical, Chemical, or Process Engineering.
- Minimum of 7 years’ experience in pyrolysis, gasification, or other thermochemical conversion technologies, with at least one system successfully taken from design through to operation.
- Proficient in SolidWorks, including assemblies, sheet metal design, weldments, and production drawing creation.
- Demonstrated experience with FEA and/or CFD analysis on high-temperature equipment.
- Strong understanding of heat transfer, fluid mechanics, combustion, and biomass reaction kinetics.
- Excellent technical writing skills and experience collaborating closely with fabricators.

Preferred Qualifications

- Familiarity with biochar standards such as EBC or IBI, or knowledge of carbon removal methodologies.
- Experience with syngas cleanup, bio-oil condensation, or combined heat and power (CHP) integration.
- Hands-on experience in fabrication or commissioning of pyrolysis or related systems.

This role offers the opportunity to lead innovative projects in renewable energy and waste-to-value technologies, contributing to sustainable solutions while developing your leadership and technical expertise.