Staff Chemical Engineer, Thermal Processing Specialist

About Redwood Materials

Redwood is localizing a global battery supply chain that seamlessly integrates recovery, reuse, and recycling — keeping critical minerals in circulation and driving the energy transition. Founded in 2019, we’re delivering low-cost and large-scale energy storage and producing battery materials in the U.S. for the first time, all from batteries we already have.

Position Summary:

We are seeking a highly experienced and technically proficient Staff Chemical Engineer – Thermal Process Specialist to lead the design, development, and optimization of high-temperature thermal processing systems for metallurgical applications. This role will serve as a Subject Matter Expert (SME) in high-temperature reactor and process design, providing critical insights into technology selection, system design, materials of construction, process control, and safety.

Key Responsibilities:

• Serve as the SME for high-temperature thermal processing technologies, with a focus on metallurgical applications.
• Evaluate and compare thermal processing routes for a variety of feedstocks, identifying key design parameters, trade-offs, and performance metrics.
• Direct development of new high-temperature processes, including bench-scale testing, pilot plant design, and scale-up strategies.
• Scope and define bench-scale testwork programs, including selection of appropriate lab-scale equipment and test conditions to simulate industrial thermal processes.
• Specify materials of construction for thermal reactors and associated systems, considering temperature, corrosion, erosion, and mechanical stresses.
• Develop process control strategies for high-temperature systems, including instrumentation selection, control logic, and integration with plant automation systems.
• Model and simulate thermal processes using process and thermodynamic modeling tools to predict system behavior, optimize performance, and support scale-up.
• Analyze high-temperature chemical reactions, including molten phase behavior, combustion chemistry, and solid-gas interactions relevant to metallurgical processes.
• Prepare and review detailed engineering documentation, including:
  • Block Flow Diagrams (BFDs)
  • Process Flow Diagrams (PFDs)
  • Heat and Mass Balances
  • Equipment Specifications
  • Engineering Calculations
  • Piping and Instrumentation Diagrams (P&IDs)
• Participate in HAZOP studies and other process safety reviews to identify and mitigate hazards associated with thermal systems
• Collaborate with safety and compliance teams to ensure thermal systems meet internal and external safety standards, including combustible dust, flammable gases, and thermal runaway risks
• Provide technical support during commissioning, startup, and troubleshooting of thermal processing systems

Required Qualifications:

• 10–15 years of experience in high-temperature processing systems (>500°C) within a metallurgical or related industrial environment.
• Proven expertise in the design, commissioning, and operation of a wide range of thermal processing equipment, including:
  • Kilns
  • Furnaces
  • Dryers
  • Roasters
• Strong background in material handling, feed/discharge systems, off-gas treatment, and dust collection associated with high-temperature operations.
• Experience with both direct-fired and indirect-fired thermal systems.
• Minimum 5 years of experience linking engineering design with bench and pilot-scale testing to develop and optimize thermal processes.
• Direct experience in selecting and qualifying ceramic and metallic materials for use in high-temperature systems.
• Proficiency in process modeling (HSC Chemistry, METSIM, Aspen, or similar) and thermodynamic simulation software (FactSage, MPE or similar).
• Deep understanding of process safety and hazard mitigation strategies for high-temperature operations.
• Familiarity with relevant regulatory codes and standards (e.g., ASME, NFPA) governing thermal systems and fuel delivery infrastructure.
• Strong understanding of combustion, pyrolysis, and phase transformation phenomena in high-temperature envir