Upstream Process Development Scientist Jobs in Washington

Process Development Scientist, Carbon Materials

Hands-On Pilot Scale-Up and Manufacturing Development

Location: Gaithersburg and Walkersville, Maryland (fully on-site position)

Build a First-of-Its-Kind Domestic Carbon Platform

An advanced materials venture in Maryland is developing a proprietary carbon conversion process designed to establish a domestic supply of high-performance synthetic graphite and related carbon materials. The company currently operates an active R&D wet lab in Gaithersburg and is commissioning a larger pilot manufacturing facility in Walkersville. This role will help translate validated chemistry into repeatable pilot-scale operations and establish the technical foundation for future commercial expansion.

This is not a pure research role. You will work hands-on across the R&D lab and pilot facility, helping convert validated carbon chemistry into repeatable operating conditions, commissioned equipment, and scalable manufacturing processes.

What You Will Do

In this hands-on scale-up role, you will:

• Translate bench-validated chemistry into pilot-scale operating conditions
• Define, test, and refine process parameters and material performance targets
• Support equipment selection, process design, acceptance testing, installation, and commissioning
• Develop and execute structured test plans to improve yield, consistency, and repeatability
• Interpret material characterization data using techniques such as XRD, Raman, SEM, and GDMS
• Troubleshoot high-temperature thermal processing and chemical purification systems
• Develop SOPs, technical documentation, safe operating practices, and repeatable workflows
• Analyze process and material data to identify variability, root causes, and optimization opportunities
• Collaborate closely with operations personnel, engineers, and senior technical leadership

What Success Looks Like

At 6 months:

• Core pilot equipment installed and progressing through commissioning
• Initial operating parameters and material targets defined and tested
• Structured testing, documentation, and troubleshooting frameworks in place
• Early process risks and sources of variability identified

At 12 months:

• Stable, repeatable pilot production achieved
• Process variability reduced through structured experimentation
• Data-driven optimization methods incorporated into routine development work
• Technical foundation and operating windows established to support commercial replication

What You Bring

We are targeting technical talent with 4–8 years of relevant experience — including graduate research and postdoctoral work — who are ready to step into expanded ownership within a pilot-scale, high-growth environment. Time spent in graduate school conducting relevant research counts fully toward this range.

We are primarily targeting recent PhD graduates and postdoctoral researchers coming out of relevant graduate programs.

Candidates with equivalent industry experience will also be considered, and may currently hold titles such as:

Research Scientist • R&D Scientist • Materials Scientist • Process Development Engineer • Process Engineer • Chemical Engineer • Postdoctoral Researcher

• Experience in graphite is welcome but not required. Of particular value is experience with:Coal cleaning, demineralization, or beneficiation, including froth flotation or related mineral-processing techniques
• Carbon fiber development using pitch-based, coal-derived, or oil-derived precursors
• Activated carbon, porous carbon, coke, coal, pitch, or related carbon materials
• Rare earth chemical separation and slurry-based processing
• Acid leaching, chemical purification, or mineral extraction circuits
• High-temperature ceramics, boron, or refractory materials processing
• Powder handling, particle processing, and purification systems

Candidates whose carbon-related experience comes from solid (coke, coal) or liquid (pitch) feedstocks are preferred over those working primarily with gas-phase carbon precursors (e.g., acetylene, CO2)

The strongest candidates will demonstrate:

• Experience bringing new processes or pilot plants online in early-stage environments
• Technical depth paired with practical, hands-on execution
• Experience defining process parameters and troubleshooting material or process variability
• Comfort working with equipment, test systems, and evolving operating procedures
• Ownership mindset with long-term growth orientation
• The ability to receive mentorship while contributing independently within a small technical team
• Experience supporting the startup, commissioning, or scale-up of a new process or pilot system is highly valuable but not required.

Education

We are primarily targeting recent PhD graduates or postdoctoral researchers in Chemical Engineering, Materials Science, Fuel Science, or a related discipline. Candidates with a Bachelor's or Master's degree will also be considered, provided they bring relevant industry experience in carbon materials, thermal processing, chemical purification, or process development.

Operating Environment

This is an early-stage pilot-scale operation. Success requires

• :Comfort operating in a small team, fast-moving build environment while helping establish and refine core systems
• A willingness to work hands-on in both laboratory and pilot-facility environments
• Sound technical decision-making in a small, high-accountability team
• Adaptability as equipment, priorities, and operating procedures evolve
• Strong collaboration with technical leadership, operations, vendors, and external partners

Travel

Minimal expected travel; primarily facility-based in Maryland, supporting both the Gaithersburg lab and Walkersville pilot facility.

Compensation & Benefits

• Base Salary: $130,000–$150,000, commensurate with experience
• Bonus: 10% annual performance bonus
• Eligible for Long-Term Incentive plan
• Medical, dental, and vision insurance
• Retirement plan
• Paid time off and additional company-sponsored benefits

Work Authorization

Candidates must qualify as a U.S. Person under applicable U.S. export control regulations. This generally includes U.S. citizens, U.S. permanent residents, and certain protected individuals. Visa sponsorship is not available for this position.

Equal Opportunity Employer

Our client is an equal opportunity employer committed to building a diverse and inclusive workforce. All qualified applicants will receive consideration without regard to race, color, religion, sex, national origin, sexual orientation, gender identity or expression, age, disability, protected veteran status, or any other characteristic protected by applicable law.