Lead Engineer, Process Design

About the role

AIRCO is a world leader in carbon conversion technology, transforming CO₂ into valuable synthetic fuels via its proprietary AIRMADE™ platform. The company has commercial partnerships with airlines such as JetBlue and Virgin Atlantic, and has secured government contracts with NASA and the U.S. Department of Defense’s Defense Innovation Unit. AIRCO’s innovations have been recognized with awards including Time Best Inventions, Inc. Best in Business, Fast Company World Changing Ideas, the XPrize for Carbon Removal, the EPA Green Chemistry Challenge Award (October 2023), and the World Economic Forum UpLink Sustainable Aviation Challenge. The Lead Engineer, Process Design will report to the Manager of Engineering and be based in New Britain, PA.

Responsibilities

• Lead the development of Process Design Packages for new technologies from AIRCO R&D, providing the technical basis for FEL, FEED, and detailed engineering performed by EPC contractors.
• Lead process synthesis, simulation, and design; generate material & heat balances; select and design equipment; create PFDs and P&IDs; produce equipment data sheets; perform process hydraulics calculations; conduct HAZOP reviews for commercial units based on carbon‑dioxide conversion technologies.
• Serve 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 all AIRCO‑developed technologies and processes.
• Represent AIRCO in external meetings; present engineering solutions, technical recommendations, and process‑design packages.
• Develop engineering standards and work practices; mentor internal teams; promote a safe, collaborative, and high‑quality engineering environment.

Requirements

• Bachelor's degree in chemical engineering required; advanced degree preferred.
• 10‑15 years of design experience in refining, petrochemical, chemical, gas processing, or a related process industry.

Qualifications

• Expertise in industry‑standard process simulation modeling: Aspen Plus, HYSYS.
• Expertise in 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.

Benefits

• Comprehensive Health Benefits – full coverage for employee base premiums on health, dental, and vision insurance; 70% coverage for spouse and dependent base premiums; choice between base or enhanced plans.
• Health Savings & Flexibility – company‑sponsored HSA and FSA accounts for healthcare and dependent care expenses.
• Income Protection & Insurance – company‑paid Short‑Term Disability; optional Long‑Term Disability and Life Insurance plans.
• Time Off & Leave – flexible and generous paid time off with carry‑over option; paid family leave for important life moments.
• Retirement Savings – tax‑deferred 401(k) plan with a 3% company match.
• Lifestyle & Commuter Benefits – monthly Lifestyle Spending Account for eligible work‑from‑home and commuting expenses (gas, parking, public transit); pre‑tax commuter benefits via Navia for transit and parking.
• Additional Perks – ancillary benefits through Sequoia (pet insurance, financial wellness programs); employee wellness program inclusive of Wellhub & One Medical; company‑sponsored events promoting an inclusive, values‑driven workplace; weekly company‑funded meal stipend for restaurant and food‑delivery services.

Schedule

Based in New Britain, PA; works on‑site three days per week.