Terrion is an advanced carbon materials company developing the Carbonyx process — a proprietary system that converts U.S. domestic anthracite into synthetic graphite powder, graphite blocks, and graphene. Terrion’s mission is to establish a fully domestic synthetic graphite supply chain that counters U.S. dependence on Chinese graphite, serving defense, nuclear energy, and advanced industrial markets.
Terrion is part of the IBX portfolio, founded by Dr. Kam Ghaffarian, which builds and supports advanced technology companies aligned with national security, civil space, and strategic infrastructure.
This is not a mature plant management position. It is a Director-level role for someone who can own both the operational and technical process dimensions of a first-of-kind pilot facility — and build the systems that scale it to commercial production.
Reporting to the CTO, the Director of Operations & Process Development will hold unified accountability for pilot plant operations and process development. This role bridges operational leadership with hands-on technical execution: running the facility, owning the process, and building the knowledge base required for commercial replication.
The successful candidate will commission the facility, establish operational discipline, and directly lead the translation of validated Carbonyx bench chemistry into stable, repeatable pilot-scale production. They will manage a small team of technicians and operators while collaborating closely with a Technical Lead (PhD-level) who reports to the CTO and owns characterization, structured test plan execution, and process optimization workstreams.
• Lead pilot facility commissioning, daily production operations, and throughput stabilization
• Oversee equipment installation, startup, acceptance testing, and operational readiness across all Carbonyx processing circuits
• Establish and own SOPs, safety protocols, and operating discipline across chemical, thermal, and powder handling systems
• Build and manage a small team of technicians and operators; develop talent and embed safety culture
• Coordinate maintenance, troubleshooting, and system optimization; own uptime and reliability targets
• Implement process monitoring, quality controls, and production reporting systems
• Translate bench-validated Carbonyx chemistry into stable pilot-scale operating conditions; own process parameter definition and refinement
• Oversee structured test plans targeting yield improvement, process consistency, and material quality
• Interpret and apply material characterization data (XRD, Raman, SEM, GDMS) to drive process decisions
• Troubleshoot high-temperature thermal processing systems (graphitization to 2,600°C) and chemical purification circuits (acid leach)
• Develop technical documentation, operating procedures, and process knowledge base in forms directly transferable to commercial-scale replication
• Identify scale-up risks early and establish mitigation strategies grounded in pilot data
• Collaborate closely with the CTO and senior technical leadership to align operations with Carbonyx process development objectives
• Coordinate with engineering subcontractors, equipment vendors, and Owner’s Representative during facility buildout
• Support federal program reporting and data deliverables, including DoD and DOE cost-share program milestones
• Collaborate closely with the Technical Lead (CTO-reporting) on process optimization workstreams, ensuring operational and technical development efforts are coordinated and mutually reinforcing
• Pilot equipment installed and safely commissioned
• Core operating systems, safety protocols, and monitoring systems operational
• Initial Carbonyx process parameters defined, tested, and documented
• Structured troubleshooting framework and production reporting system in place
• Stable pilot throughput achieved with documented operating conditions
• Process variability reduced; data-driven optimization underway
• Operational discipline and safety rigor embedded across the facility and team
• Technical documentation complete and structured for commercial scale transfer
• Operational and process foundation established for 1,500 tpa commercial Phase 1 scale-up
• 12 to 18 years of combined operations and process development experience in advanced materials, chemical processing, or industrial manufacturing environments
• Demonstrated experience commissioning new equipment or facilities in pilot or early-commercial environments
• Direct supervisory responsibility for technical teams
• Track record translating R&D-stage processes into stable production systems
Strong candidates will have direct experience in one or more of the following:
• High-temperature thermal processing (graphitization, sintering, calcination, ceramics, refractory materials)
• Chemical purification systems including acid leaching and slurry-based processing
• Powder handling, size classification, and purification circuits
• Carbon, graphite, or advanced ceramic materials processing
• Rare earth separation, boron processing, or other critical materials environments
Direct graphite processing experience is a strong advantage but not required.
• Ability to read, interpret, and apply material characterization outputs (XRD, Raman, GDMS) to process decisions
• Familiarity with process instrumentation, control systems, and data-driven process optimization
• Strong safety and regulatory discipline in chemical and thermal operating environments (NFPA 660, dust hazard, F-2/H-occupancy or equivalent)
Bachelor’s degree in Chemical Engineering, Materials Science, Mechanical Engineering, or related discipline required. Advanced degree (MS or PhD) in a relevant field welcomed and will be weighted in evaluation. Equivalent hands-on leadership experience in lieu of advanced degree considered where technical depth is demonstrated.
Terrion is an early-stage operating company. The pilot facility is being built from the ground up. This role requires:
• Comfort operating in a fast-moving build environment while establishing core systems and process discipline
• Strong judgment in a small, high-accountability team where decisions directly shape the trajectory of the company
• Prior startup, pilot plant, or first-of-kind facility experience is highly valued
Minimal expected travel. This is a facility-based role at 36 W. Pennsylvania Ave., Frederick, Maryland.
This position supports U.S. Government programs that may involve Controlled Unclassified Information (CUI) and/or export-controlled technologies. Candidates must be able to comply with all applicable U.S. export control laws and regulations. Eligibility to obtain required authorizations or security clearances may be required in the future.
Terrion is an equal opportunity employer committed to building a diverse and inclusive workforce. All qualified applicants will be considered without regard to race, color, religion, sex, national origin, sexual orientation, gender identity or expression, age, disability, protected veteran status, or any other characteristic protected by applicable law.