Process Engineer - Furnace

ETCH is a startup commercializing a radically new and efficient decarbonization technology for the simultaneous greenhouse gas-free production of hydrogen and solid carbon from natural gas.

The Process Engineer position at ETCH, INC will be focused on development and optimization of our current processes, as well as supporting our scale-up efforts.

Primary duties include: the optimal design, performance, efficiency, and safety of the processes, while driving continuous improvements and innovations.

Other duties include:

• Design thermal processes: Develop and design furnaces and furnace improvements for specific materials or processes. Design and integrate heating systems, including electric elements tailored to process requirements.

• Thermal modeling: Use simulation software (e.g., ANSYS, COMSOL, or CFD tools) to model heat transfer, combustion, fluid flow, and temperature distribution inside the furnace.

• Material selection: Specify appropriate refractory materials, insulation, and structural components for furnace linings and housings.

• Efficiency improvements: Identify ways to reduce energy consumption, increase thermal efficiency, and minimize heat losses.

• Process control: Define instrumentation and control strategies (temperature sensors, feedback loops, PID tuning) to ensure stable operation.

• Prototype testing: Participate in commissioning and testing of furnace systems; validate thermal performance against design specs.

• Data analysis: Monitor and interpret thermal profiles, gas flows, emissions, and process parameters for continuous improvement.

• Prepare documentation: Create P&IDs, process flow diagrams, technical specifications, and operation manuals.

• Regulatory compliance: Ensure designs comply with safety standards, environmental regulations (e.g., emissions control), and industry codes (e.g., ASME, API, NFPA).

• Work with engineering team: Collaborate on integration with mechanical systems and solids handling.

• Liaise with vendors: Evaluate and manage suppliers of furnace components and subsystems.

• Failure analysis: Investigate and resolve furnace failures, overheating, or uneven heating issues and recommend and implement system upgrades.

• Prevent workplace safety hazards by system recommendations, implementation, and routine inspections

Tools/Software Experience

• Simulation: ANSYS, COMSOL, Fluent, SolidWorks Flow Simulation

• CAD/Design: SolidWorks, PTC Creo, Catia

• Control systems: PLC programming tools (Siemens, Allen-Bradley), SCADA

• Data analysis: Excel, MATLAB, Python (for thermal data)

Preferred Qualifications:

• Bachelor’s degree or higher in Chemical Engineering or related field

• 10+ years of experience in process engineering,

• Experience with furnace operation, design, and optimization in industries such as metallurgy, glass manufacturing, ceramics, or petrochemicals.

• Background in thermodynamics, fluid dynamics, and heat transfer.

• Strong analytical and problem-solving skills

• Excellent communication and teamwork abilities

• Must be able to work safely and follow safety precautions in industrial environments (temperature, humidity, noise, confined spaces, etc.).

• Strong analytical and problem-solving skills with a data-driven approach

• Experience with process simulation software and statistical analysis tools preferred

• Knowledge of relevant industry standards and environmental regulations

The ability to work independently as well as in a team environment toward timely execution of goals is required.

ETCH is committed to equal opportunity for its employees. To that end, ETCH does not discriminate on the basis of sex, gender, marital status, pregnancy, race, color, ethnicity, national origin, age, disability, religion, sexual orientation, gender identity or expression, veteran status or other legally protected characteristic. ETCH is committed to providing qualified individuals access to all employment programs, benefits and activities on the basis of demonstrated ability, performance and merit without regard to personal factors that are irrelevant to the program involved.

Compensation commensurate with relevant experience.