Process Modeling Engineer

Position Overview

Zero Carbon Systems seeks a Process Modeling Engineer to bridge theoretical modeling, process design, and plant operations, leveraging our internal process and equipment models to develop a highly rigorous techno-economic analysis (TEA) that our leadership team will use to finalize operating points for the ZCS demo and production facilities. Using existing heat and mass balances and capital estimates, this engineer will optimize the process across scenarios such as weather, location, and plant configuration, improve process design through research and design review, and sharpen capital estimates through direct vendor feedback and informed equipment selection. The ideal candidate will have strong TEA experience for highly integrated industrial processes, hands-on process engineering experience in an industrial setting, and the ability to communicate complex numerical results clearly to leadership, investors, and external reviewers. This full-time position can be based in Brighton, Colorado or performed remotely, and reports to the Process Modeling Lead.

Responsibilities Include:

• Use and develop internal process modeling tools to guide the selection of operating points for the ZCS demo and production facilities based on operating cost, capital cost, and energy efficiency
• Continuously update and refine ZCS process models based on design improvements, operational data, and material advances, including running and optimizing our Aspen Custom Modeler (ACM) model
• Translate Aspen process models into an Excel output that generates the system equipment list, equipment sizing (max/min/nominal), stream list, pipe sizing, power demand, and stream tables, and automate it using VBA or similar tools to rapidly populate vendor-ready equipment specification sheets and run self-consistency checks
• Work with appropriate personnel to translate model outputs into Aspen Capital Cost Estimator (ACCE) and related cost estimation tools, and diligently compare internal capital estimates against those generated by external design firms
• Use ACCE estimates and vendor quotes to specify equipment and area basis costs, sizing basis, and scaling exponents for the larger system TEA model, and develop shortcut models to support quick process review and analysis
• Partner with internal drafters and designers to keep Process Flow Diagrams (PFDs) and Piping and Instrumentation Diagrams (P&IDs) aligned with the latest process model, and communicate model, process, and equipment updates to our external engineering design firm
• Ensure all design and equipment updates are integrated into the demo facility design and build, and provide insight from experience and vendor interactions on equipment selection and relative pricing to drive down capital cost and increase process efficiency
• Identify opportunities to reduce system energy, CapEx, and OpEx through fundamental process design optimization and rigorous TEA, working with domain leads in materials, site operations, and mechanical engineering to scope projects that test those opportunities and translate findings back into the model
• Collaborate with engineering, R&D, and project management to integrate process models and cost data into larger project workflows, identify critical impact variables and data quality gaps, and support Life Cycle Analysis and environmental impact assessments
• Present model findings, cost estimates, and process updates to senior leadership, investors, and other stakeholders

Requirements Include:

• Degree in chemical engineering or a related field; graduate degree preferred
• 7+ years of experience post undergraduate degree (BS + 7 years, MS + 5 years, or PhD + 2 years)
• Prior TEA experience for highly integrated industrial processes
• Prior hands-on process engineering experience in an industrial setting or chemical manufacturing plant
• Knowledge of methods for representing and modeling heat and mass transfer in porous materials
• Proficiency with Excel, VBA, Python, JMP, or similar tools to maximize the functional utility of model outputs
• Strong analytical thinking, problem solving, and troubleshooting skills, with excellent communication, reporting, and presentation skills
• Preferred: process operations and/or design exposure, with demonstrated experience reading and generating PFDs, P&IDs, equipment lists, and instrument lists
• Preferred: experience with detailed design and equipment selection or procurement
• Preferred: experience working with cross-functional teams, scoping new R&D or engineering projects, and working at a startup moving from R&D to testing and scale-up
• Preferred: experience communicating complex numerical results to a non-technical audience