Senior Process Engineer; Direct-air-capture

Senior Process Engineer (Direct-air-capture)

Join to apply for the Senior Process Engineer (Direct-air-capture) role at Rivan Industries
.

This role focuses on the end-to-end design of one of the most innovative direct air capture (DAC) process systems. You will deploy a new system each week, ensuring minimal bureaucracy and full ownership of the design, safety, build, and operation cycle.

About us: Rivan Industries () is a synthetic fuel company aimed at decarbonising heavy industry. We design modular synthetic fuel plants with a lime-based DAC system, an alkaline electrolyser, and a Sabatier reactor, integrating DC solar and the European gas grid. Our DAC loop uses a cyclic CaO/Ca(OH)₂/CaCO₃ cycle.

• System architecture selection and process modelling (FEED) for a cyclic lime-based DAC process.
• Design and optimisation of unit operations across the full CaCO₃ → CaO → Ca(OH)₂ → CaCO₃ loop, including calcination, carbonation contractors, hydrators, dryers, and solids handling.
• Full system scope including inter‑unit solids transport, steam generation, CO₂ handling, methanation and electrolysis integration.
• Ideate novel reactor architectures and solids‑processing approaches.
• Intelligent, inherently safe design of high‑temperature, steam‑rich, solids‑handling systems.
• Develop bench‑scale test rigs, oversee testing and analyse data for calcination, hydration, carbonation and sorbent cyclic stability.
• Design gas‑solid reactors/contractors, milling and classification systems.
• Perform system‑wide process optimisation and steady‑state modelling (e.g. Aspen) of high‑temperature reaction kinetics, mass/heat balances and cyclic performance.
• Create and own PFDs and P&IDs for DAC systems.
• Define control strategies for DAC in steady‑state and transient operation.
• Specify and procure components for high‑temperature and solids‑handling equipment.

• Lead HAZID, HAZOP, LOPA, SIF specification and DSEAR.
• Ensure end‑to‑end process safety across the lime‑based DAC system.

• Factory assembly, acceptance testing and on‑site installation of DAC modules.
• Commissioning, startup, and operational data analysis to optimise conversion, energy consumption and cyclic performance.
• Review unit performance versus targets and feed into next design iteration.

• 5+ years of professional experience.
• Bachelor’s or Master’s degree in Chemical Engineering or related field.
• Experience designing and building plants with solids.
• Strong background in solid‑handling (screws, feeders, mills, classifiers, silos, cyclones) and gas‑solid reaction systems.
• Experience with high‑temperature processes (calcination, pyrolysis, reforming, roasting, thermal treatment).
• Experience with powders/granular materials (attrition, flowability, cohesion, PSD control).

• Process plant design, commissioning and operation experience.
• Experience in lime, cement, sorbents, ceramics or mineral processing industries.
• Leadership in HAZID, HAZOP and LOPA.
• Process modelling expertise (Aspen or equivalent steady‑state).
• Control system design, ideally for solids‑handling or thermal processes.
• Bench‑scale experimental design, data acquisition and gas‑solid reactor testing.
• CAD competence.
• Chartered Engineering status.

• £70‑100k salary depending on experience.
• Significant share options as part of the early team.
• In‑person work at HQ in South Bermondsey, South London; flexibility considered.
• Extensive relocation support, including £6,000 per year extra for living near HQ.
• Unlimited time‑off.

Mid‑Senior level

Full‑time