The Process Engineer - Fuel Forms provides engineering support for the development, scale-up, and operation of advanced fuel form manufacturing processes. This role supports research and development through full-scale production, focusing on coating processes, powder handling and forming, furnaces, and associated chemical and material systems. The position collaborates closely with process development, manufacturing, and facility teams to ensure safe, efficient, and compliant fuel form production.
Responsibilities- Assist with the development, design, optimization, and day-to-day operation of fuel form manufacturing processes, including coating applications, graphite or ceramic powder preparation, powder compaction, and sintering or furnace-based operations.
- Create and maintain detailed manufacturing documentation such as process flow diagrams, piping and instrumentation diagrams, equipment layouts, operating conditions, and formal process specifications.
- Conduct process modeling, material and energy balance calculations, and data analysis to support scale-up efforts, performance optimization, and issue resolution.
- Contribute to the evaluation, selection, specification, and purchasing of manufacturing equipment, including furnaces, coating equipment, presses, material handling systems, chemical processing equipment, and supporting utilities.
- Operate and support process equipment during commissioning, qualification, design verification, and validation activities.
- Support the implementation of process automation and material handling solutions, including the integration of sensors, control systems, and data collection tools.
- Develop, update, and maintain standard operating procedures, work instructions, and training materials for fuel form manufacturing operations.
- Perform root cause investigations and drive corrective actions for process issues related to equipment performance, process deviations, and product quality concerns.
- Assist with quality assurance efforts, including audits, inspections, and documentation reviews, to ensure compliance with applicable safety and regulatory standards.
- Work closely with facilities, mechanical, and utilities engineering teams to ensure manufacturing process requirements are properly incorporated into facility and infrastructure designs.
- Support continuous improvement initiatives aimed at improving yield, throughput, reliability, safety, and cost efficiency.
- Participate in hazard analyses and safety reviews involving chemical processing, thermal systems, and material handling operations.
- Maintain clear, professional, and accurate technical communication and documentation across internal and external stakeholders.
- Provide technical support and mentorship to junior engineers and technicians involved in fuel form manufacturing processes.
- Collaborate with cross-functional teams to standardize engineering procedures, documentation practices, and operational workflows.
- Perform additional responsibilities as assigned by leadership.
Requirements: - A Bachelor's degree in Chemical, Materials, Mechanical, or Nuclear Engineering from an ABET EAC-accredited program is required.
- Five or more years of relevant professional experience is preferred; advanced degrees may substitute for a portion of the required experience.
- Demonstrated experience in process development, manufacturing operations, or pilot-scale production environments is required.
- Hands-on experience with powder handling, coating operations, furnace systems, thermal processing, or chemical manufacturing equipment is highly desirable.
- Proven ability to develop, read, and interpret process flow diagrams, piping and instrumentation diagrams, equipment specifications, and related process documentation.
- Experience supporting the installation, commissioning, and troubleshooting of manufacturing or process equipment.
- Working knowledge of applicable manufacturing, chemical, and safety codes, standards, and regulations.
- Familiarity with process control systems, automation technologies, and data acquisition or data management tools.
- Experience using 2D and or 3D engineering and manufacturing software tools is preferred.
- Strong analytical, problem-solving, and technical documentation skills.
Benefits:All eligible employees enjoy an excellent benefits package, including medical/dental/vision insurance, short/long-term disability, life insurance, 401(k), paid time off including holidays, and tuition reimbursement.
