Lead Engineer, Process Design

AIRCO is seeking a Lead Engineer, Process Design to provide technical leadership across engineering flowsheet development, process simulation, and process design deliverables. In this on-site role in Doylestown, PA, you will collaborate with R&D, operations, EPC contractors, customers, and other engineering disciplines to support projects from development through startup, helping translate carbon dioxide conversion technologies into commercial-ready package sets.

Reporting to the Manager of Engineering, you will help drive process synthesis, simulation, equipment selection and design, and the generation of core documentation such as PFDs and P&IDs. The position requires the experience to lead complex engineering work and communicate assumptions, findings, risks, and recommendations in cross-functional settings.

Key Responsibilities

• Lead the development of Process Design Packages for new technologies created by AIRCO’s research and development organization.
• Lead process synthesis, simulation, and design, including material and heat balances, equipment selection and design, and generation of PFDs and P&IDs.
• Develop equipment data sheets and complete process hydraulics calculations for commercial units.
• Facilitate HAZOP reviews for commercial units tied to carbon dioxide conversion technologies developed by AIRCO.
• Act as the primary process-engineering liaison among R&D, operations, EPC contractors, customers, and other engineering disciplines throughout project development, construction support, commissioning, and startup.
• Support process-economic evaluations, cost estimates, project planning, and technical decision-making by clearly communicating assumptions, findings, risks, and recommendations.
• Ensure compliance with applicable engineering standards, internal design guidelines, and environmental, health, and safety regulations for AIRCO-developed technologies and processes.
• Represent AIRCO in external meetings by presenting engineering solutions, technical recommendations, and process-design packages.
• Develop engineering standards and work practices, mentor internal teams, and promote a safe, collaborative, high-quality engineering environment.

Required Qualifications

• Bachelor’s degree in chemical engineering (advanced degree preferred).
• 10-15 years of design experience in refining, petrochemical, chemical, gas processing, or a related process industry.
• Expertise in industry-standard process simulation modeling using Aspen Plus and HYSYS.
• Expertise generating commercial-scale heat and material balances, PFDs, P&IDs, equipment specifications, datasheets, hydraulics, and Process Design Packages.
• Strong knowledge of process equipment design, development, sizing, and selection.

Technologies

• Aspen Plus
• HYSYS

Benefits

• Full coverage for employee base premiums on health, dental, and vision insurance.
• 70% coverage for spouse and dependent base premiums.
• Choice between base plans or enhanced options.
• Access to company-sponsored HSA and FSA accounts.
• 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.
• Tax-deferred 401(k) plan with a 3% company match.
• 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 including Wellhub and One Medical.
• Company-sponsored events and programs supporting an inclusive, values-driven workplace.
• In-person weekly catered lunch every Wednesday.

About the Role and Work Setup

• This role is part of the Engineering department and works closely with scientists, engineers, and the operations team.
• Work location is New Britain, PA, with on-site work three days per week.

Working at AIRCO

At AIRCO, you will work as part of a team of engineers, scientists, operators, builders, and innovators tackling hard problems with tangible impact. The organization builds and deploys real systems for fuel and chemical production in real-world conditions, emphasizing safety, teamwork, transparency, purpose, agility, ambition, and creativity.