Controls Engineer - Hertha Metals

About Hertha Metals, Inc.:

Hertha Metals is redefining how the world makes steel. We’ve developed a breakthrough single-step steelmaking process that uses gas reductants to convert iron ore of any grade or form, delivering lower production costs and emissions than blast furnaces-while improving product quality and scalability. Having operated the world’s largest single-step steelmaking pilot plant, we’re now scaling toward commercial deployment. Our mission is to redefine the foundation of modern industry by scaling cleaner, more efficient, and more cost competitive metalmaking systems. At Hertha, engineers, metallurgists, and operators work side by side to transform the future of steel making.

Controls Engineer

The Controls Engineer will support the design, commissioning, operation, and continuous improvement of the automation and control systems critical to Hertha’s ironmaking process. This role requires a hands-on engineer who is comfortable working in an industrial, plant-based environment and collaborating closely with operations, maintenance, and cross-functional engineering teams during scale-up. This position reports directly to the Director of Plant Engineering.

Key Responsibilities

• Support the design, specification, and implementation of control systems, including PLCs, DCS, HMI/SCADA platforms, safety instrumented systems (SIS), and industrial networks

• Develop, test, and maintain PLC and HMI programs, control narratives, functional specifications, cause-and-effect matrices, and I/O lists

• Design and implement control strategies for furnace operation, gas handling, material handling, and other process systems, including PID loops, sequencing, interlocks, and permissives

• Support factory acceptance testing (FAT), site acceptance testing (SAT), commissioning, and start-up activities

• Provide on-site troubleshooting and engineering support for control systems during operations

• Lead or assist with root cause analysis (RCA) of control system issues and process upsets, and implement corrective actions

• Tune control loops and optimize process performance in collaboration with process engineers and operations

• Develop and maintain alarm management, data historian, and process data collection systems to support operations and continuous improvement

• Ensure compliance with applicable codes, standards, and safety requirements (e.g., ISA-88, ISA-18.2, IEC 61131, IEC 61511, ISA/IEC 62443)

• Participate in safety reviews, HAZOPs, LOPAs, and incident investigations

• Collaborate with process, mechanical, and instrumentation and electrical engineers to ensure integrated system performance

• Support controls engineering needs for plant expansions and future facilities, including standardization of control system architecture and programming practices

Your Experience

• BS or higher in Electrical, Controls, Chemical, or Mechanical Engineering

• 2+ years of relevant experience in industrial automation and control system design, programming, and commissioning. Experience in steelmaking operations is desirable.

• Experience in new plant engineering or plant process engineering with a focus on plant operations and start-ups

• Ability to make well-balanced judgments by weighing functionality, reliability, initial investment, and ongoing expenses

• Understanding of complex interactions between feedstocks and upstream and downstream processes is highly desirable

• Strong analytical skills with the ability to define problems, collect data, establish facts, draw valid conclusions, and implement sustainable improvements

• Ability to clearly communicate and present status, actions, recommendations, and other technical information at all levels

• Capacity to build strong relationships with and positively influence equipment vendors and system integrators

Additional Skills

• Support furnace commissioning, control tuning, and optimization activities

• Proficiency with PLC programming platforms (e.g., Rockwell Studio 5000, Siemens TIA Portal) using ladder logic, function block, and structured text

• Experience with HMI/SCADA and historian platforms (e.g., Ignition, FactoryTalk, WinCC, OSIsoft PI)

• Familiarity with industrial communication protocols and networks (e.g., Ethernet/IP, Modbus TCP, Profinet, OPC UA)

• Familiarity with combustion and burner management systems (BMS) and NFPA 86 requirements

• Familiarity with scripting languages (e.g., Python, SQL, MATLAB) for data analysis and automation

• Knowledge of advanced process control concepts (e.g., cascade, feedforward, ratio, and model-based control) is a plus

• Working knowledge of instrumentation and electrical systems sufficient to read P&IDs, loop diagrams, and electrical schematics

• Demonstrated ability to adapt to changing priorities and thrive in a fast-paced, experimental environment

• 3-8 years of experience in an industrial, manufacturing, energy, metals, or chemical environment, with hands-on experience supporting control systems in operating facilities

• Strong troubleshooting and problem-solving skills

• Willingness to work on-site and support plant operations, including off-hours support during commissioning and start-up, as required

PERSONAL ATTRIBUTES

Energetic and highly motivated; high level of organization; able to multitask on many projects; detail oriented; able to focus on overall project goals; team oriented.

LEVEL OF INDEPENDENCE

Individuals must be able to work independently and also be able to direct long-term tasks through to completion. Some projects are highly supervised, some are minimally supervised.

If you’re hiring for both roles, I’d also soften the PLC programming and HMI/SCADA bullet in the I&E description to “familiarity with,” so the two descriptions divide responsibilities cleanly and candidates can tell which one fits them. The same “2+ years” versus “3-8 years” inconsistency carries over here from the original template, so you may want to settle on one range for both postings.

Location: Hertha Metals’ headquarters are in Conroe, TX, just outside of Houston.

Hertha Culture:

Inspired by the work and character of the late Hertha Ayrton, we are pioneers, innovators, and risk-takers who are mission driven towards changing the world. We are:

• Mission-Obsessed - We are deeply committed, driven, and passionate about achieving our mission of being the catalyst for decarbonizing metals production.

• Anti-Bloat - We operate as a lean, efficient agile team to maximize impact.

• Leave the “I” at home - We face challenges together, knowing that collaboration and unity are the keys to our success.

• Safety First - Safety is our top priority in everything we do! NO EXCEPTIONS.

• Aim High - We achieve what others consider impossible.

What we offer:

• Competitive startup compensation package based on expertise. Compensation is increased based on achieved business development milestones.

• Stock: ownership in a funded company that is innovating in a trillion-dollar industry

• Paid + unpaid parental leave after 1 year at the company (12 weeks paid, with flexible working style to transition after parental leave such as part-time remote working)

• Growth: our team is comprised of people with a growth mindset, and we want to help you achieve your future career goals accordingly

• Time off: This is a fast-paced startup company working in one of the most exciting sectors and the last thing we want is our valuable team members to burn out.

• 401k plan for employees that have been employed with us for at least a year.

Hertha Metals is an Equal Opportunity Employer. We firmly prohibit discrimination and harassment of any kind. In fact, we uniquely hold our shareholders and board members to higher standards than the majority of companies. All employment decisions at Hertha Metals are based on the expertise that the position calls for, without regard to race, religion, sex, gender identity, disability, sexual orientation or age.