Senior Process Development Engineer Jobs in Austin, TX

We are seeking a highly experienced Senior Process Technology Engineer to play a pivotal role in advancing our seawater-to-jet fuel pilot plant and preparing the technology for commercial scale-up. This is a hands-on technical leadership position focused on operational excellence, capital project execution, and technology evaluation in the emerging Power-to-Liquid / e-fuels sector. The ideal candidate will bring deep process engineering expertise, preferably in carbon capture, syngas chemistry, or synthetic fuel production and will thrive in a dynamic, fast-paced environment where pilot-scale innovation directly informs multi-million-dollar scale-up decisions.
What We Offer
• The opportunity to shape the future of sustainable aviation fuel at the intersection of cutting-edge science and commercial deployment.
• Competitive compensation package:
• Salary $150K - $190K annual
• Health, Dental, and Vision Insurance
• Short- and Long-Term Disability and Term Life Plan
• 401(k) retirement plan with employer contribution
• Paid Time Off (PTO)
• Paid Holidays and Sick Leave
• A collaborative, mission-driven culture focused on innovation and climate impact.
Key Responsibilities
1. Operational Technical Support for a Seawater-to-Jet Fuel Pilot Plant (Direct Ocean Capture)
• Deliver process engineering support to ensure safe, reliable, and optimized operation of the pilot facility.
• Troubleshoot process upsets, perform root-cause analysis, and implement corrective actions for key unit operations including CO₂ capture, hydrogen production/integration, syngas synthesis, Fischer-Tropsch synthesis, and product upgrading.
• Monitor process data, develop and maintain performance metrics, and drive continuous improvement initiatives to increase yield, reduce downtime, and improve energy efficiency.
• Support HAZOPs, safety reviews, and management-of-change (MOC) processes for pilot-plant modifications.• Collaborate closely with operations, maintenance, and analytical teams to translate pilot data into actionable insights.
2. Leadership of CAPEX Projects (up to $5-100 million)
• Lead multidisciplinary capital projects from concept through commissioning, including feasibility studies, front-end engineering design (FEED), detailed design, procurement, construction, and start-up.
• Develop project scopes, cost estimates, schedules, and risk registers; ensure projects are delivered on time, on budget, and meet technical and safety requirements.
• Manage external engineering firms, vendors, and contractors while maintaining strict cost and schedule control.
• Conduct post-project evaluations and capture lessons learned to refine future scale-up strategies.
3. Identification and Vetting of Critical Technologies for Future Scale-Up
• Scout, evaluate, and recommend emerging and commercially ready technologies in CO₂ capture/utilization, hydrogen integration, synthesis gas generation, synthetic fuel synthesis, and downstream refining/upgrading.
• Assist in techno-economic analyses (TEA) modeling, technology readiness level (TRL) assessments, and risk evaluations to support go/no-go decisions for scale-up deployment.
• Build and maintain technology roadmaps that align pilot learnings with commercial plant design basis.
• Establish and manage relationships with technology providers, universities, and research organizations.
• Prepare technical reports, white papers, and presentations for internal stakeholders and potential investors or partners.
Required Qualifications
• Bachelor's or Master's degree in chemical engineering or mechanical engineering (or equivalent).
• Minimum 10 years of progressive process engineering or process technology experience in the chemical, petrochemical, refining, or energy industries.
• Demonstrated experience in pilot-plant or demonstration-scale operations, preferably involving high-pressure, high-temperature, or gas-to-liquids processes.
• Proven track record leading capital projects valued up to $5 million (or equivalent scope).• Strong working knowledge of process simulation tools (Aspen Plus/HYSYS, UniSim, or equivalent), process flow diagrams (PFDs), P&IDs, and heat & material balance development.
• Excellent analytical, problem-solving, and communication skills with the ability to influence cross-functional teams.
• Ability to travel occasionally to vendor sites, testing facilities, or future commercial locations (estimated 10-30%).
Preferred Qualifications
• Direct experience in Sustainable Aviation Fuel (SAF), CO₂ capture and utilization (CCU), Power-to-Liquid (PtL), Fischer-Tropsch synthesis, or related synthetic fuel / carbon-recycling technologies.
• Background in hydrogen production, electrolysis integration, and/or gas purification systems.
• Familiarity with relevant industry standards (API, ASME, NFPA) and process safety management (PSM).
• Experience working in a startup or scale-up environment is highly desirable.