Senior Process Engineer, Energetics (Continuous Flow, RDX)

JOB DESCRIPTION

Senior Process Engineer, Energetics (Continuous Flow RDX)

Department

Programs

Program

Continuous Flow RDX Production Program

Reports To

Deputy Head of Programs

Location

Ballinger, TX

Work Arrangement

Primarily on-site

Travel

As required to vendor, contractor, and equipment sites

FLSA Status

Exempt

Employment Type

Full-time

Direct Reports

None (directs daily activities of assigned technicians and mentors the Process Engineer, Energetics (CF HMX))

Clearance

Not required (active Secret or ability to obtain preferred)

POSITION SUMMARY

Critical Materials Group (CMG) is developing advanced domestic energetic material manufacturing capabilities through a Continuous Flow RDX production system designed to improve safety, reproducibility, scalability, and manufacturing resilience. The Senior Process Engineer, Energetics serves as the senior technical execution lead and primary engineering authority for day-to-day execution of the RDX Program, coordinating facility construction, equipment installation, process integration, automation implementation, commissioning, startup, and operational readiness. This role is the technical integrator between process designers, automation providers, equipment vendors, construction contractors, Production, Operations, and Government stakeholders. Because CF RDX is the foundational manufacturing capability for multiple future CMG programs, this individual will set technical and execution standards that will be leveraged across subsequent programs, including CF HMX, PAX52, and AIME Formulation/LAP.

KEY RESPONSIBILITIES

Program Execution

▪ Serve as the on-site technical lead for the Continuous Flow RDX program.

▪ Execute program activities in accordance with approved cost, schedule, and technical baselines.

▪ Support development and maintenance of detailed execution schedules.

▪ Identify technical, schedule, and execution risks and recommend mitigation strategies.

▪ Support program reviews, milestone demonstrations, and sponsor engagements.

Facility Construction & Integration

▪ Act as CMG’s engineering representative during facility construction activities.

▪ Coordinate installation of process equipment, utilities, environmental systems, and supporting infrastructure.

▪ Ensure facility layouts support operational, safety, maintenance, and production objectives.

▪ Coordinate with Operations personnel on site readiness requirements.

▪ Participate in construction acceptance and turnover activities.

Process Implementation & Optimization

▪ Serve as the primary engineering interface for externally developed process designs.

▪ Evaluate process designs for manufacturability, scalability, operability, and maintainability.

▪ Lead implementation of process modifications needed to support operational requirements.

▪ Identify opportunities to improve yield, throughput, product quality, and operational efficiency.

▪ Support process hazard analyses and operating procedure development.

Automation & Digital Integration

▪ Coordinate closely with the Automation & Digital Systems team.

▪ Support development of:

○ Process control strategies

○ Instrumentation requirements

○ Data collection architectures

○ Process monitoring systems

○ Operational dashboards

▪ Ensure process requirements are translated into automation requirements.

▪ Support validation of automation and control systems during commissioning.

Vendor & Contractor Management

▪ Manage technical interactions with:

○ Equipment suppliers

○ Automation vendors

○ Construction contractors

○ Engineering support contractors

▪ Review technical deliverables and equipment specifications.

▪ Participate in factory acceptance testing and site acceptance testing.

▪ Ensure vendor activities remain aligned with program objectives.

Commissioning & Startup

▪ Lead commissioning planning and execution activities.

▪ Develop startup plans and readiness checklists.

▪ Coordinate dry runs, integrated system testing, and operational demonstrations.

▪ Resolve technical issues arising during startup.

▪ Lead troubleshooting efforts during commissioning and initial operations.

Production Readiness

▪ Coordinate closely with Production and Operations organizations.

▪ Develop operating procedures and engineering work instructions.

▪ Support technician and operator training.

▪ Ensure systems are transitioned with complete documentation and supporting data.

▪ Support production readiness reviews and turnover activities.

Technical Data Package Development

▪ Support development and maintenance of Technical Data Packages (TDPs).

▪ Ensure engineering documentation remains current and configuration-controlled.

▪ Review:

○ PFDs

○ P&IDs

○ Equipment specifications

○ Control narratives

○ Operating procedures

○ Maintenance procedures

▪ Support creation of production transition documentation.

Safety & Compliance

▪ Support explosives safety analyses and regulatory approvals.

▪ Ensure compliance with:

○ OSHA Process Safety Management requirements

○ Environmental regulations

○ Explosives safety requirements

○ Site operating procedures

▪ Participate in hazard analyses and risk assessments.

▪ Promote a strong safety culture across all project activities.

Leadership

▪ Direct daily activities of assigned technicians.

▪ Coordinate matrixed resources from:

○ Production

○ Operations

○ Automation & Digital Systems

○ Safety & Compliance

○ Finance & Contracts

▪ Mentor junior engineers, including the Process Engineer, Energetics (CF HMX).

▪ Establish engineering and execution best practices that can be replicated across future CMG manufacturing programs.

WHAT SUCCESS LOOKS LIKE

First 12–18 months

▪ Successfully integrated facility, equipment, and automation systems.

▪ Led commissioning and startup of the Continuous Flow RDX production capability.

▪ Established the technical baseline for future CMG energetics manufacturing efforts.

▪ Implemented robust process monitoring and data collection capabilities.

▪ Delivered complete Technical Data Packages and operational documentation.

▪ Enabled successful transition of the capability to Production and Operations.

▪ Established engineering processes and lessons learned leveraged by the HMX, PAX52, and AIME/LAP programs.

QUALIFICATIONS

Required

▪ Bachelor’s degree in Chemical Engineering, Chemistry, Process Engineering, or a related technical discipline.

▪ 5+ years of progressively responsible engineering experience.

▪ Experience supporting design, construction, startup, or operation of industrial process facilities.

▪ Experience leading multidisciplinary technical teams.

▪ Experience managing contractors, vendors, and external engineering organizations.

▪ Experience with hazardous chemical or energetic material processes.

Technical Skills

▪ Process scale-up and manufacturing implementation.

▪ Process troubleshooting and optimization.

▪ Commissioning and startup planning.

▪ Process safety management.

▪ Technical documentation development.

▪ Risk identification and mitigation.

Preferred

▪ Master’s degree or Ph.D. in Chemical Engineering, Chemistry, or a related discipline.

▪ Experience with nitration chemistry, energetic materials, explosives, propellants, or munitions manufacturing.

▪ Experience with continuous-flow chemical processing.

▪ Experience with automation, PLC systems, and industrial controls.

▪ Experience supporting DDESB approvals and explosives safety programs.

▪ Experience supporting government-funded manufacturing programs.

▪ Active Secret clearance or the ability to obtain one.

WORKING CONDITIONS & PHYSICAL DEMANDS

▪ Primarily on-site supporting CF RDX facility construction, commissioning, and startup activities.

▪ Travel as required to vendor, contractor, and equipment sites.

EMPLOYMENT REQUIREMENTS

▪ Successful completion of a background check and drug screening

COMPENSATION & BENEFITS

Base salary: To be determined. This role is also eligible for CMG’s full benefits package.

EQUAL EMPLOYMENT OPPORTUNITY

Critical Materials Group is an equal opportunity employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, age, disability, protected veteran status, or any other characteristic protected by law.