Staff Process Development Engineer
Who We AreElectra is reinventing ironmaking from the ground up with a breakthrough electrochemical technology that produces high purity clean iron and critical co-minerals. With two operating pilots in Boulder and a new demonstration facility underway in Jefferson County, we’re on track to reach commercial scale by the end of the decade. Backed by over $300 million and strategic partnerships with global leaders across mining, steel, and big tech, momentum is on our side. Recognized by Fast Company as a Most Innovative Company and a Next Big Thing in Tech, and named one of TIME’s 100 Climate Leaders, we’re building a company shaping the future of industry. If you’re looking to make an impact and join a team that’s driven, focused, and scaling, we want to hear from you.What You Will DoThe Staff Process Development Engineer will provide technical leadership for the development, design, and scale-up of chemical and hydrometallurgical processes across a range of scales, from bench-scale proof-of-concept through Electra’s pilot and demonstration facilities. This role will serve as a senior technical resource within process engineering, driving complex development efforts, shaping technical approaches, and partnering across engineering teams to support sound technical decisions as Electra advances toward commercial-scale operations.Responsibilities IncludeProvide technical leadership for complex process development and scale-up projects from laboratory through pilot and demonstration scale Design and guide development of chemical process systems, including mass and energy balances, P&IDs, equipment specifications, fabrication, and commissioning Develop technical approaches for process development and scale-up using engineering principles, modeling, and experimental data Lead process safety activities, including HAZOPs, FMEAs, and other hazard reviews Partner across mechanical, electrical, controls, and other engineering disciplines to define requirements and support technical decisions Analyze complex experimental and process data and translate findings into recommendations that guide engineering and business decisions Lead commissioning, troubleshooting, and optimization of equipment and process systems to improve safety, reliability, and performance Advance process development and engineering practices through documentation, practical standards, and knowledge sharing Serve as a trusted technical resource and mentor, providing guidance on complex process engineering challenges Maintain a safe working environment and lead safety assessments for new equipment, processes, and operations Read, understand, and comply with all workplace health and safety policies, safe work practices, and company policies and procedures Perform other duties as assigned What We Need You To Bring To The TeamBachelor’s degree in chemical engineering, mining/metallurgical engineering, chemistry, or a related field 12+ years of relevant industry experience; OR 8+ years with a Master’s degree; OR 5+ years with a PhD; or equivalent experience (excludes internships, co-ops and other school projects) Deep experience in process design, including mass and energy balances, reaction kinetics, thermodynamics, separations, and fluid flow Demonstrated ability to provide technical leadership on complex process engineering projects and serve as a trusted subject-matter resource Proven ability to influence technical decisions and collaborate effectively across engineering disciplines and functions without relying on formal authority Demonstrated success implementing safety measures for gas- and liquid-processing systems and leading process safety reviews Expert proficiency with process simulation software and the ability to use models to inform experimental design, predict outcomes, and guide process development and scale-up Strong ability to analyze complex experimental data, recognize meaningful patterns, develop technical recommendations, and communicate results clearly to both technical and non-technical teams Solid experience in analytical chemistry and applying it to troubleshoot complex experimental issues, evaluate alternatives, and determine appropriate technical approaches Strong understanding of fluid power systems, including pumps, valves, and heat-exchange equipment, and how they integrate into larger mechanical and process systems Hands-on experience using power tools and basic fabrication methods to build or modify custom equipment supporting testing, development, and process improvement Experience coordinating with external vendors, providing technical guidance, tracking progress, and ensuring contracted work meets quality, schedule, and project objectives Demonstrated ability to improve engineering practices, share knowledge, and contribute to the technical development of others Proficient in, or able to quickly pick up, Microsoft Office applications including Word, Excel, PowerPoint, Outlook, OneDrive, and SharePoint to create clear documentation and support project needs CompensationThe anticipated starting pay range for this position is $135,000-$185,000 and may be more or less depending upon skills, experience, and education. Benefits For You100% paid premiums across all medical, dental, vision, telemedicine, short-term disability, long-term disability, and basic life insurance plans$1,800 in annual employer HSA contributions (health savings account) Benefits For Your Family100% paid premiums across all medical, dental, vision, and telemedicine plans 12 weeks of paid parental leave Benefits For Your Future401k with up to 5% matching contributions which vest 100% on day one Eligibility for incentive stock options If you need an accommodation during the application or interview process, reach out to us at careers@electra.earth We’re here to help.