Lead Process Engineer in Wales

About the Company: Our client is a pioneering technology company based in South Wales, developing scalable, sustainable processes for converting waste materials and solvents into high-value advanced materials and clean energy vectors. Their patented technology supports the circular economy by transforming hard-to-recycle inputs into performance-critical products used across energy, infrastructure, and advanced manufacturing applications. The company is rapidly scaling operations and developing next-generation conductive materials, composites, and building products that outperform conventional alternatives and support decarbonised infrastructure. They value practical problem-solving, bold innovation, and strong multidisciplinary collaboration, offering the opportunity to work at the forefront of industrial process scale-up within a high-growth environment.

Role Summary: The Lead Process Engineer will own and develop the organisation’s chemical and process engineering capability for a high-temperature materials production process. Working closely with senior technical leadership, engineers, and process scientists, the role focuses on scaling reactor-based thermal and chemical processes from development into pilot and production operations. Responsibilities include planning and overseeing production trials, analysing performance data, and implementing process improvements to increase throughput, quality, and robustness, while maintaining a strong safety culture in a fast-growing organisation.

Key Responsibilities:

• Lead the definition and delivery of the process development programme in collaboration with senior technical leadership, including experimental design, execution, and success metrics.
• Provide chemical and process engineering leadership for high-temperature reactor-based processes, including heat and mass transfer, reactor design, and scale-up considerations.
• Use process simulation and modelling tools (e.g. COMSOL, Aspen, CFD or similar) to understand and optimise operating conditions and inform equipment, controls, and scale-up strategy.
• Act as the link between lab-scale development, IP/patents, and pilot or production operations, translating learning into robust operating envelopes and standard operating procedures.
• Identify and deliver process enhancements to meet product performance, yield, throughput, and cost targets across multiple product variants and applications.
• Work closely with operations, data, mechanical, and controls engineering colleagues to diagnose process issues, manage risks, and design modifications to equipment and systems.
• Lead and contribute to process safety activities (e.g. HAZOPs, risk assessments), ensuring safe operating windows are defined, maintained, and continuously improved.
• Support and mentor engineers and technicians, helping to build strong process engineering capability and a culture of continuous improvement.

About You:

Essential:

• Degree in Chemical Engineering (or closely related discipline) or equivalent industrial experience.
• Typically 5+ years’ experience in process or chemical engineering within an industrial environment (e.g. chemicals, materials, energy, or similar).
• Proven experience taking processes from lab or pilot scale into larger-scale operation.
• Strong ability to analyse process data, design and run trials, and implement changes safely and systematically.
• Familiarity with process safety tools and methods (e.g. HAZOP, risk assessments, safe systems of work).
• Experience using at least one process or thermal simulation tool (e.g. COMSOL, Aspen, CFD, HYSYS or similar).

Desirable:

• Experience in high-temperature processes, thermal reactors, or advanced materials manufacturing.
• Background in a startup, scale-up, or fast-changing manufacturing environment.
• Experience mentoring or guiding engineers and technicians.
• Knowledge of hydrogen, gas handling, or hazardous area operations.

What’s on Offer:

• Competitive compensation package based on skills and experience (£50,000, negotiable depending on experience).
• Eligibility to participate in an employee share options scheme.
• Tailored training and career development programme, including structured mentorship in an engineering-led organisation.
• Opportunity to make a significant technical and strategic impact within a high-growth company, working closely with senior technical leadership and founders.

The company is committed to building a diverse and inclusive workplace and welcomes applications from women, people from under-represented backgrounds in engineering, and those returning to work or changing career paths. Candidates who may not meet every listed requirement but feel they could thrive in this role and contribute meaningfully are strongly encouraged to apply. The organisation operates in a fast-paced, high-trust environment that values accountability, collaboration, and sustainable ways of working.