Lead Process Development Engineer

Our client is seeking a highly accomplished Lead Process Development Engineer to join their innovative team in **Seattle, Washington, US**. This critical role will focus on designing, optimizing, and scaling chemical processes for novel material production. You will be responsible for leading projects from conceptualization through to pilot-scale and eventual commercialization, ensuring safety, efficiency, and cost-effectiveness at every stage. The ideal candidate will possess a deep understanding of chemical engineering principles, reaction kinetics, separation technologies, and process simulation. You will oversee the development of process flow diagrams (PFDs), piping and instrumentation diagrams (P&IDs), and equipment specifications. Collaboration with R&D scientists, project managers, and manufacturing teams will be essential to translate laboratory discoveries into viable industrial processes. Your responsibilities will include conducting hazard and operability studies (HAZOPs), performing mass and energy balances, and developing robust control strategies. You will also play a key role in troubleshooting process issues, implementing continuous improvement initiatives, and ensuring compliance with all relevant environmental, health, and safety regulations. The Lead Process Development Engineer will mentor junior engineers, share technical expertise, and foster a culture of innovation and best practice within the engineering department. This is a hands-on role requiring strong problem-solving skills, excellent communication, and the ability to manage multiple priorities in a fast-paced environment. A proven track record in process scale-up and commercialization within the chemical or materials industry is essential. Experience with statistical process control (SPC) and Six Sigma methodologies is highly desirable.

Responsibilities: Lead the design and development of new chemical processes. Oversee process scale-up from lab to pilot and commercial scale. Develop PFDs, P&IDs, and equipment specifications. Conduct process safety analyses (e.g., HAZOP). Perform mass and energy balances and process simulations. Collaborate with R&D, project management, and manufacturing teams. Troubleshoot and optimize existing chemical processes. Mentor and guide junior process engineers. Ensure compliance with safety and environmental regulations. Manage process development project timelines and budgets. Qualifications: Ph.D. or Master's degree in Chemical Engineering or a related field. 10+ years of experience in process development and scale-up within the chemical industry. Extensive knowledge of chemical reaction engineering, separation processes, and thermodynamics. Proficiency in process simulation software (e.g., Aspen Plus, HYSYS). Strong understanding of process safety principles and HAZOP studies. Experience with pilot plant operations and troubleshooting. Excellent leadership, communication, and interpersonal skills. Demonstrated ability to manage complex projects. Experience with statistical process control and Six Sigma is a plus.