Thermal Mechanical Engineer - Job Description
Baltimore, MD Full-time
Primary duties include leading the design and development of advanced reactor systems and supporting infrastructure. This role will be central to scaling from pilot to commercial systems, with a strong emphasis on reactor bundles, high-temperature design, and balance-of-plant (BOP) integration. Focus will be on design, improving performance and efficiency, and safety of the processes all while driving continuous improvements and innovations.
Other duties include:
Reactor & Core System Design
- Design and optimize annulus reactor bundles, including thermal uniformity, flow distribution, and mechanical integrity
- Develop detailed mechanical designs for pilot reactor modifications and scale-up to 5 MTPD (metric tons per day) reactor systems
- Perform thermal and structural calculations for high-temperature operation (61000b0C environments)
- Evaluate materials of construction considering creep, thermal expansion, and chemical compatibility
Structural & Mechanical Systems
- Design structural supports for reactor systems, accounting for thermal expansion, vibration, and load conditions
- Ensure mechanical robustness and maintainability of reactor assemblies
- Develop expansion joints, supports, and interfaces between hot and cold sections
Balance of Plant (BOP) & Layout
- Lead mechanical design and layout for balance-of-plant systems, including:
- Heat exchangers
- Piping systems
- Valves and flow control
- Gas handling systems
- Develop plant layout and equipment arrangement for pilot and commercial facilities
- Ensure proper integration between reactor core and BOP systems
Engineering Analysis & Optimization
- Conduct thermal modeling (CFD/FEA preferred) and heat transfer analysis
- Perform stress analysis and lifecycle evaluation of critical components
- Support optimization of system efficiency, uptime, and reliability
Execution & Scale-Up
- Support transition from pilot to commercial-scale systems
- Work closely with fabrication teams, vendors, and operations
- Participate in installation, commissioning, and troubleshooting
Qualifications:
- Education: Bachelor's or Master's degree in Mechanical Engineering or related field
- 5+ years of experience in: High-temperature systems, Reactor design / process equipment, Thermal systems engineering
- Experience with chemical plants, hydrogen systems, pyrolysis, or similar is highly preferred
- Strong fundamentals in: Heat transfer, Fluid mechanics, Structural mechanics
Experience with: - CAD tools (SolidWorks, Inventor, or similar)
- FEA/CFD tools (ANSYS, COMSOL, etc.)
- High-temperature alloys, ceramics, and refractory materials
- Pressure systems and piping design codes (ASME preferred)
Preferred Attributes
- Experience designing modular or bundled reactor systems
- Familiarity with scale-up challenges (pilot 1 commercial)
- Hands-on mindset with ability to work in fast-paced startup environments
- Strong problem-solving and ownership attitude
An ability to work independently as well as in a team environment toward timely execution of goals is required.
Compensation commensurate with relevant experience.
