Staff Process Development Engineer

Who we are:  

Electra 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 do:  

The 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 include:

• Provide 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 team:   

• Bachelor’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