Senior Process Engineer (Multiple Positions), HUT290685

About the position

The Senior Process Engineer at Tesla, Inc. will lead the development activities for battery recycling, overseeing the entire process from conceptualization to the operation of pilot plants. This role involves managing day-to-day pilot operations, directing technicians, and ensuring the efficiency and safety of the process. The engineer will also be responsible for developing mass and energy balances, selecting equipment, and translating process learnings into actionable improvements.

Responsibilities

• Lead key development activities for battery recycling from process conceptualization to pilot plant operation.
• Manage day-to-day pilot operations as the primary technical contact for process steps and unit operations.
• Direct the work of technicians and operations to achieve organizational goals.
• Develop and maintain mass and energy balances for unit operations.
• Assist in sizing and selecting equipment for pilot facilities and guide commercial scale-up.
• Take ownership of pilot unit areas and oversee material production.
• Procure, commission, and optimize pilot equipment.
• Translate material and process learnings into actionable results such as process guidance and design criteria.
• Ensure day-to-day process operation is safe, organized, and efficient.
• Assemble production plans, data collection strategies, and report-out.

Requirements

• Bachelor's degree in Materials Science, Chemical Engineering, Materials Engineering, or related field (foreign educational equivalent accepted).
• 3 years of experience in process development and scale-up, including R&D.
• Experience in pilot plant development design, drafting, construction, and operation.
• Direct experience in lithium-ion battery recycling, mechanical processing, black mass upgrading, and off-gas management.
• Experience working in kilo-scale laboratory or development environments.
• Ability to develop FEL2 process design packages including PFD's, P&ID's, 3D layouts, and equipment cost estimates.
• Familiarity with analytical techniques for battery active materials such as FTIR, M/S, ICP-MS, or ICP-OES.
• Experience with manufacturing processes and rapid prototyping.
• Proficiency in 3D CAD software (SolidWorks/CATIA) and 2D drafting software (AutoCAD).
• Ability to build mass/energy balances for process plants.
• Knowledge of chemical processes including filtration, thermal processing, liquid reactors, crystallizers, milling, blending, powder conveying, wastewater treatment systems, and electrochemical processing.
• Experience with process simulation software and mechanical/electrical drawings.