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AIRCO · 20 hours ago

Sr. Development Engineer

New Britain, Pennsylvania, United States

Full-time

Onsite

Senior Level

AIRCO is a world leader in carbon conversion technology, paving the way to global energy security by transforming CO₂ into a valuable resource. The Senior Development Engineer will play a critical role in commercializing AIRCO’s Sustainable Aviation Fuels technology, focusing on experimental development and scale-up processes.

Carbon CaptureChemicalGreenTechManufacturing

No H1B

Security Clearance Required

Responsibilities

Design, plan, and execute pilot-unit and bench-scale testing programs to support SAF process development and scale-up

Operate, troubleshoot, and optimize reaction and separation systems, identifying root causes of performance deviations

Develop experimental strategies to close data gaps critical for commercialization readiness

Handle and interpret large, complex experimental datasets, identifying trends and correlations

Develop mechanistic yield, reaction, and separation models grounded in thermodynamics and transport fundamentals

Integrate experimental data with numerical, statistical, and simulation tools to improve model accuracy and predictability

Utilize and interpret data from analytical equipment (e.g., GC, HPLC, spectroscopy, physical property measurements)

Ensure data quality, reproducibility, and traceability to support design decisions and scale-up

Translate experimental results into actionable inputs for EDI/BEDP delivery

Support technology readiness progression from development through demonstration and early commercial deployment

Collaborate with cross-functional teams including R&D, engineering, operations, and project management

Apply a creative, hypothesis-driven approach to solving complex technical challenges

Identify opportunities for process improvement, risk reduction, and performance optimization

Contribute to intellectual property development, technical documentation, and knowledge transfer

Qualification

Chemical EngineeringExperimental DevelopmentThermodynamicsData AnalysisPilot-Scale TestingProcess DevelopmentNumerical ToolsTroubleshooting SkillsFuels ExperienceInnovationProblem SolvingCollaboration

Required

M.S. or Ph.D. in Chemical Engineering, Mechanical Engineering, or a closely related discipline

Significant experience in hands-on experimental development, pilot-scale testing, or process development

Strong grounding in thermodynamics, reaction engineering, and separation fundamentals

Demonstrated ability to analyze large datasets and extract mechanistic insight, not just empirical fits

Experience with numerical tools, simulation software, or data analysis platforms (e.g., Aspen, MATLAB, Python, similar)

Proven troubleshooting skills in experimental or pilot-plant environments

Experience in fuels, petrochemicals, refining, catalysis, or sustainable energy technologies

Familiarity with scale-up challenges, process modeling, and commercialization workflows

Experience supporting or delivering EDI / FEL engineering packages

Preferred

Knowledge of SAF pathways and regulatory or sustainability considerations is a plus

Benefits

Full coverage for employee base premiums on health, dental, and vision insurance.

70% coverage for spouse and dependent base premiums.

Access company-sponsored HSA and FSA accounts to save on healthcare and dependent care expenses.

Company-paid Short-Term Disability insurance.

Optional Long-Term Disability and Life Insurance plans.

Flexible and generous paid time off, including national holidays and sick leave.

Paid family leave to support you during important life moments.

Tax-deferred 401(k) plan with a 3% company match to help you invest in your future.

Pre-tax savings on transit and parking, plus monthly company contributions.

Ancillary benefits through Sequoia, including pet insurance and financial wellness programs.

Employee wellness program to support your well-being.Inclusive of Wellhub & One Medical.

Company-sponsored events and programs that promote an inclusive and values-driven workplace.

In person weekly catered lunch every Wednesday.

Company

AIRCO

AIRCO is a world leader in carbon conversion technology, paving the way to global energy independence and security by transforming CO₂ into a valuable resource.

Founded in 2016