Staff Process Design Engineer - Material Handling

Who You Are

As a Process Design Engineer within Sila’s Capital Projects team, you will contribute to the development and implementation of first-of-its-kind, auto-scale battery material manufacturing facilities. You are a creative, diligent, and hands-on technical contributor who understands the process lifecycle—from initial feasibility and conceptual design through commissioning.

In this role, you will apply your process engineering toolkit to take next-generation technology and transform it into robust manufacturing units. You will be responsible for the design of unit operations and shepherding those designs through detailed engineering for both new plants and retrofits. You will work seamlessly with multiple internal engineering teams and external partners to drive engineering execution and related procurement, ensuring process systems meet safety requirements, performance specifications, and cost targets. You will join a diverse team that starts with first principles to design and qualify processes for commercial production, collaborating closely with Research, Development and Engineering, Manufacturing, and EHS&S representatives to meet Sila’s manufacturing scaling objectives.

Responsibilities and Duties

• Serve as a main point of contact for process engineering inquiries, with a focus on bulk material handling systems (conveying, blending, screening, and packaging), from conceptual design through detailed design, construction, start-up, and initial operation.
• Execute design projects to close gaps or settle issues encountered in design
• Shepherd unit operation designs through detailed engineering, generating Heat and Material Balances (HMBs), PFDs, P&IDs, Process Control Narratives, equipment datasheets, and other project and operating documentation.
• Lead and support process safety deliverables, including HAZOP recommendation closure, MOC changes, safety system designs, and operational alarm management.
• Identify gaps in capital project execution, commissioning or asset operation through close observation and foresight. Raise these gaps to relevant responsible parties and assist in closure where appropriate.

Knowledge and Skill Requirements

• Bachelor’s or Master’s degree in Chemical Engineering, Mechanical Engineering, or related field.
• 6+ years of industrial experience in process design, commissioning, and operations, preferably within powders, chemicals, or advanced materials manufacturing. Experience with bulk material handling, pneumatic conveying, blending, screening and packaging systems is highly preferred.
• Strong familiarity with regulatory, safety, and environmental compliance requirements, including NFPA, API, ASME, OSHA, and related standards.
• Proficiency in process modeling software such as ASPEN, HYSYS, or equivalent simulation tools.
• Hands-on process design experience including the generation of Heat and Material Balances (HMBs), preliminary equipment sizing, and P&ID development.
• Practical experience with basic control schemes and a functional understanding of advanced control strategies.
• Familiarity with safety-critical instrumentation, pressure relief systems, and operational alarm management.
• Experience navigating risk management protocols, including Management of Change (MOC) and participating in HAZOP studies.
• Proven ability to work independently as a technical contributor while collaborating effectively within a multi-disciplinary project team.
• Willingness to travel to project sites and external design offices to support design reviews, construction, and commissioning activities.
• Demonstrate a conscientious, curious, and deliberate approach to complex problem-solving.

Physical Demands and Working Conditions

• Must be able to remain in a stationary position to operate a computer and other office productivity machinery, such as a laptop, copier/printer machine, etc.
• Wear personal protective equipment including, but not limited to, a hard hat, lab coat or coveralls, gloves, safety glasses, and safety shoes
• Pass a respirator fit test and be able to wear respiratory protection on a periodic basis
• Move long distances and occasionally kneel or bend
• Up to 50% travel for work at new production site during construction, commissioning and startup
• Up to 10% travel during other time periods

The starting base pay for this role is between $151,000 and $191,000 at the time of posting. The actual base pay depends on many factors, such as education, experience, and skills. Base pay is only one part of Sila’s competitive Total Rewards package that can include benefits, perks, and equity. The base pay range is subject to change and may be modified in the future.
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