ThermalMechanicalEngineer

ETCH, INC Thermal Mechanical Engineer – Job Description Baltimore, MD Full-time ETCH is a startup commercializing a radically new and efficient decarbonization technology for the simultaneous greenhouse gas-free production of hydrogen and solid carbon from natural gas. Primary duties include leading the design and development of advanced reactor systems and supporting infrastructure. This role will be central to scaling from pilot to commercial systems, with a strong emphasis on reactor bundles, high-temperature design, and balance-of-plant (BOP) integration. Focus will be on design, improving performance and efficiency, and safety of the processes all while driving continuous improvements and innovations. Other duties include: Reactor & Core System Design Design and optimize annulus reactor bundles, including thermal uniformity, flow distribution, and mechanical integrity Develop detailed mechanical designs for pilot reactor modifications and scale-up to 5 MTPD (metric tons per day) reactor systems Perform thermal and structural calculations for high-temperature operation (≥1000°C environments) Evaluate materials of construction considering creep, thermal expansion, and chemical compatibility Structural & Mechanical Systems Design structural supports for reactor systems, accounting for thermal expansion, vibration, and load conditions Ensure mechanical robustness and maintainability of reactor assemblies Develop expansion joints, supports, and interfaces between hot and cold sections Balance of Plant (BOP) & Layout Lead mechanical design and layout for balance-of-plant systems, including: Heat exchangers Piping systems Valves and flow control Gas handling systems Develop plant layout and equipment arrangement for pilot and commercial facilities Ensure proper integration between reactor core and BOP systems Engineering Analysis & Optimization Conduct thermal modeling (CFD/FEA preferred) and heat transfer analysis Perform stress analysis and lifecycle evaluation of c