Staff Process Development Engineer

About this role

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 y ou’re looking to make an impact and join a team t hat’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

Compensation:

• The 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 You:

• 100% 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 Family:

• 100% paid premiums across all medical, dental, vision, and telemedicine plans

• 12 weeks of paid parental leave

Benefits For Your Future:

• 401k 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.

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