Senior Process Engineer, R&D

Are you ready to build America’s energy future? Form Energy is an American manufacturing and energy technology company. We’re revolutionizing energy storage with cost-effective, multi-day technology designed to keep the electric grid secure and reliable, even during extended periods of stress. By strengthening the electric system and reimagining what’s possible, we’re giving clean energy a whole new form! 

In recent years, Form Energy has earned a number of accolades, including being named by TIME as a “Best Invention”, MIT Technology Review as a “Top Climate Tech Company To Watch”, and Fast Company as “One of the Next Big Things In Tech”. We are making rapid progress on our mission of delivering energy storage for a better world, and our team is growing just as rapidly to meet demand. We have signed contracts with leading electric utilities across the United States. Trial production of our iron-air batteries has already begun, and this year, production will take off to high volumes at our new factory in West Virginia. 

Working for Form Energy is more than just a job, it’s a chance to be part of something extraordinary. And now - right as we significantly scale up battery manufacturing -  might be the most exciting moment in the company’s history to join. We are assembling a team of highly talented and driven individuals across the country. Driven by our core values of humanity, excellence, and creativity, our team is determined to deliver on our mission and transform the energy landscape for the better.

Feeling energized to make a meaningful impact on the world? Then keep reading - you’ve come to the right place.

Role Description

The Core Technology Hardware team at Form Energy is responsible for developing innovative hardware solutions across Form’s entire R&D portfolio. From developing game-changing improvements to Form’s iron-air battery technology, to conceptualizing new products, the Core Technology team charts the path forward for Form – and the Core Tech Hardware team designs, builds, and tests the hardware that makes this possible.

Form Energy is hiring a Senior Process Engineer to join this innovative team. In this role, you will work on designing, analyzing, building, and validating fluid, gas, and solids handling systems for next-generation electrochemical cells under development at Form Energy. This work may encompass a wide range of plant scales and functions, from designing and prototyping lab- and pilot-scale systems, to performing techno-economic analysis and trade studies for product-scale systems. 

This is an exciting opportunity to help shape and be part of the growth of a fast-moving company with breakthrough technology and an incredible mission!

What you'll do:

• Design fluid, gas, and solids handling systems for Form Energy’s electrochemical cells and modules. These systems may feature single-, two-phase, and multiphase flow.

• Perform analyses (e.g., FEA, CFD, thermal, structural, etc.) needed to develop your designs

• Select and source system components such as pumps, fans, valves, heaters, heat exchangers, filters, separators, pipes, etc; design custom components as needed

• Document your designs thoroughly in the form of PFDs, P&IDs, BOMs, and test reports

• Specify instrumentation and control schemes for the systems; design, build, and program control panels (yourself or in collaboration with electrical and controls engineers)

• Assemble, validate, and troubleshoot your designs for lab- and pilot-scale systems; develop operating and maintenance procedures

• Identify hazards and implement safety measures in system design

• Contribute to techno-economic analysis, conceptual plant design, and architecture trade studies for early-stage R&D efforts

What you'll bring:

• BS, MS, or PhD in Mechanical Engineering, Chemical Engineering, or a related field

• 4-7 years of experience (graduate school included) in process plant design 

• Demonstrated experience in specifying, sourcing, and operating equipment for fluid, gas, and solids handling, as well as the design and layout of associated piping and delivery systems

• Hands-on experience in testing and troubleshooting process equipment and instrumentation

• Excellent documentation, communication, and organizational skills

• Working knowledge of instrumentation and control systems, including data acquisition and programmable logic controllers (PLCs). Control panel design or PLC programming experience is a plus.

• Experience with slurry handling is a plus.

• Experience with process simulation software (e.g., SysCAD, Aspen) is a plus.