Senior Design Engineer Extraction Reactors

Senior Design Engineer Extraction Reactors Indianapolis, IN onsite only Full-time , direct hire (not a contract role) Looking for a place that is 24% to 52% LESS expensive to live with a great quality of life ? Our client is seeking a highly skilled Senior Design Engineer to lead the design, modeling, and development of an advanced magnesium metal extraction reactor. This individual will be responsible for designing and optimizing high-temperature industrial reactors using CAD software. The ideal candidate will have extensive experience in thermal systems, metallurgical processing, and reactor design, ensuring that the system operates efficiently, safely, and at scale. Responsibilities Reactor Design & Development:

• Lead the design and development of magnesium metal extraction reactors and associated processing systems.

• Utilize CAD (Siemens NX preferred) to create detailed 3D models, assemblies, and engineering drawings for manufacturing.

• Perform thermal, structural, and fluid flow analysis to optimize reactor performance and longevity.

• Select appropriate materials, coatings, and refractory linings to withstand high-temperature and corrosive environments.

CAD Modeling & Engineering Analysis:

• Develop and maintain high-precision CAD models of the reactor and supporting infrastructure.

• Conduct Finite Element Analysis (FEA) and Computational Fluid Dynamics (CFD) to validate designs.

• Optimize reactor geometry and heat transfer characteristics to improve efficiency and scalability.

Collaboration & Project Execution:

• Work closely with process engineers, metallurgists, and fabrication teams to translate designs into production-ready systems.

• Collaborate with suppliers and manufacturers to ensure feasibility, cost-effectiveness, and manufacturability of reactor components.

• Oversee prototype development, testing, and iterative design improvements.

Compliance & Safety Considerations:

• Ensure reactor design adheres to OSHA, EPA, ASME, and industry-specific safety regulations.

• Implement fail-safe mechanisms, pressure control systems, and structural reinforcements for safe operation.

• Conduct risk assessments and safety reviews related to thermal, mechanical, and chemical hazards.

Process Optimization & Innovation:

• Develop new reactor design methodologies to improve magnesium extraction yield and energy efficiency.

• Research and implement advanced manufacturing techniques for reactor fabrication and assembly.

• Stay updated on emerging technologies in metal extraction, high-temperature reactors, and industrial automation.

Qualifications

• Bachelors or Masters degree in Mechanical Engineering or equivalent.

• 5+ years of experience in reactor design, thermal systems, or metallurgical process equipment.

• Expertise in Siemens NX for 3D modeling, assemblies, and technical drawings.

• Strong background in Finite Element Analysis (FEA) and Computational Fluid Dynamics (CFD).

• Experience designing high-temperature industrial systems, furnaces, or extraction reactors.

• Knowledge of material science, heat transfer, and refractory materials.

• Familiarity with ASME pressure vessel codes, OSHA safety standards, and industrial automation.

• Excellent problem-solving, communication, and project management skills.

What the company is offering: Compensation depending on experience; $130k to $170k

• Bonus or equity

• Full medical, dental, and vision 100% paid by the company for employees and their families.

• Paid time off

• 9 holidays

Sound interesting? Send your resume to ...