Sr. Development Engineer

We are seeking a Senior Development Engineer to play a critical role in commercializing AIRCO’S  Sustainable Aviation Fuels (SAF) technology. This role is highly hands-on, combining first-principles engineering with pilot-scale execution to generate the experimental data and mechanistic models required for scale-up and Engineering Design Information (EDI) delivery.

This individual will play a key role in the design and execution of  concepting, executing, and evaluating experimental programs to enable robust yield and performance models, supporting Engineering Design Information package (EDI) delivery. The position requires close integration of experimental work, analytical characterization to build mechanistic understanding and develop solid numerical models of process reactions and separations. This role is based in New Britain, PA.

• →Develop and maintain first-principles process simulations and mechanistic models for reaction, separation, and integrated SAF production systems.
• →Apply modeling, simulation, and data analytics to predict performance, support scale-up decisions, optimize process design, and reduce commercialization risk.
• →Convert laboratory and pilot-scale results into Engineering Design Information (EDI), process design inputs, and technology performance projections.
• →Lead the development of experimental strategies and pilot campaigns required to validate models, resolve technical uncertainties, and strengthen scale-up confidence.
• →Partner with cross-functional teams to advance technology from development through demonstration and commercial deployment, while identifying opportunities for innovation and process improvement.

• M.S. or Ph.D. in Chemical Engineering, Mechanical Engineering, or a closely related discipline
• Significant experience in process development, process modeling, simulation, and scale-up engineering within chemical process industries.
• Strong grounding in thermodynamics, reaction engineering, and separation fundamentals
• Demonstrated ability to analyze large datasets and extract mechanistic insight, not just empirical fits
• Advanced experience with numerical tools, simulation software, or data analysis platforms (e.g., Aspen, MATLAB, Python, similar)
• Demonstrated experience developing first-principles, mechanistic, or hybrid process models for chemical reaction and separation systems. 
• Experience applying simulation and modeling tools to technology scale-up, process design, and commercialization decisions. 
• Ability to bridge experimental observations and engineering models to generate predictive process understanding.
• Proven ability to use engineering fundamentals, experimental data, and simulation tools to diagnose process behavior and resolve technical challenges.
• 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

• 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, with opportunities to carry over unused PTO.
• 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.