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Thermulon is a UK-based aerogel insulation company scaling from pilot to commercial-scale production. The Process Engineer role is a senior, hands-on position responsible for leading process engineering across major capital projects: an active toll-manufacturing scale-up and the design, build, and commissioning of Thermulon's first commercial-scale plant.
You will serve as the principal process owner, translating the company's strategic direction and 12–18 month milestones into actionable process engineering plans with minimal guidance. Key responsibilities include:
• Developing and owning core process engineering deliverables: process flow diagrams (PFDs), P&IDs, mass and energy balances, equipment specifications, technical bid evaluations, FAT/SAT testing plans, and commissioning documentation.
• Providing technical supervision, mentoring, and quality assurance to the process engineering team while contributing hands-on delivery.
• Applying rigorous process safety discipline: contributing engineering judgment to HAZIDs, HAZOPs, and leading safety-driven design and execution.
• Owning technical project risk registers and management-of-change (MOC) registers, driving closure through influence.
• Holding sign-off and due-diligence accountability for techno-economic analyses, ensuring models are audited, change-managed, and rigorously scrutinized.
• Leading technology transfer from lab and pilot scale into commercial production, solving creative, practical solutions to delivery challenges.
• Interfacing with R&D, Commercial, Operations, project delivery partners, external consultants, and customers in a technical capacity.
• Supporting equipment proposal development, vendor validation, and participating in trial campaigns as needed.
• Supervising and developing junior team members' technical capability while they retain ownership of their workstreams.
You will work in a small, lean organization with high autonomy, and must be willing to mobilize to UK and European sites during construction, commissioning, and early production phases.
REQUIREMENTS
Essential:
• Significant hands-on chemical process experience, including capital project delivery, technology transfer, and process scale-up.
• Demonstrable track record executing the key accountabilities listed above.
• Strong influencing skills; able to drive action from colleagues and third parties without direct line-management authority.
• Degree in Chemical or Process Engineering.
• Mobility and willingness to work at different sites for scale-up, commissioning, and early production.
Desirable:
• Chartered Engineer status (IChemE or equivalent).
• Direct experience with process hazard studies (HAZOP, HAZID, LOPA), risk management, and change management in process environments.
• Formal techno-economic analysis training (e.g., from a major energy or process company).
• Experience running equipment trials or pilot campaigns with third-party vendors.
• Experience scaling an immature or novel chemical process.
• Prior experience supervising or technically line-managing junior or graduate engineers.
• Experience managing a process development or engineering budget.
• Proven leadership of a process engineering team.
