As a Senior Research Engineer / Scientist, you will lead the research, development, and pilot-scale production of ammonium perchlorate (AP) through controlled plasma-assisted and electrochemical processes. You will be responsible for designing reactors, optimising plasma and hybrid oxidation systems, developing analytical methods, and delivering scale-up packages that underpin our next-generation propellant manufacturing capability.

You will work closely with multidisciplinary engineering teams to ensure safe, compliant, high-performance production processes within a complex energetic-materials environment.

Key responsibilities

- Design, build and commission laboratory and pilot-scale reactors for chloride/chlorate → perchlorate conversion using non-thermal plasma technologies (DBD, gliding arc, corona) and hybrid plasma–electrochemical systems.
- Optimise operating parameters and reactor internals to maximise ClO₄⁻ yield, energy efficiency, and process stability while minimising by-products.
- Integrate gas-phase plasma systems with liquid-phase capture, crystallisation, ion-exchange purification and downstream electrochemical polishing.
- Develop and validate analytical protocols for oxy-chlorine species (IC, ClOx/NOx gas analysis, TOC, pH, conductivity).
- Perform energy modelling, techno-economic assessments, and scale-up planning, identifying risks and mitigations.
- Lead safety documentation including SOPs, HAZOP inputs, oxidiser-handling controls, emissions management and regulatory notifications.
- Supervise technicians and junior engineers; liaise with vendors, external labs, and engineering partners for equipment procurement, pilot build and commissioning.

About the Role

As a Senior Research Engineer / Scientist, you will lead the research, development, and pilot-scale production of ammonium perchlorate (AP) through controlled plasma-assisted and electrochemical processes.



You will be responsible for designing reactors, optimising plasma and hybrid oxidation systems, developing analytical methods, and delivering scale-up packages that underpin our next-generation propellant manufacturing capability.

You will work closely with multidisciplinary engineering teams to ensure safe, compliant, high-performance production processes within a complex energetic-materials environment.

Key responsibilities

- Design, build and commission laboratory and pilot-scale reactors for chloride/chlorate → perchlorate conversion using non-thermal plasma technologies (DBD, gliding arc, corona) and hybrid plasma–electrochemical systems.
- Optimise operating parameters and reactor internals to maximise ClO₄⁻ yield, energy efficiency, and process stability while minimising by-products.
- Integrate gas-phase plasma systems with liquid-phase capture, crystallisation, ion-exchange purification and downstream electrochemical polishing.
- Develop and validate analytical protocols for oxy-chlorine species (IC, ClOx/NOx gas analysis, TOC, pH, conductivity).
- Perform energy modelling, techno-economic assessments, and scale-up planning, identifying risks and mitigations.
- Lead safety documentation including SOPs, HAZOP inputs, oxidiser-handling controls, emissions management and regulatory notifications.
- Supervise technicians and junior engineers; liaise with vendors, external labs, and engineering partners for equipment procurement, pilot build and commissioning.

About You

You are an experienced plasma, electrochemical,



or chemical engineer/scientist who thrives in a hands-on environment and enjoys tackling complex, first-of-a-kind technical challenges. You combine strong experimental capability with rigorous data analysis, safety leadership, and the drive to bring new energetic-materials processes from lab concept to manufacturing reality.

Essential:

- BSc or MSc with 5+ years’ experience, or PhD in plasma chemistry/engineering, electrochemistry, chemical engineering or related discipline.
- Hands-on experience operating non-thermal plasma reactors (DBD, gliding arc, corona) and/or electrochemical chlorate/perchlorate systems.
- Strong analytical laboratory experience with ion chromatography and reactive chlorine species.
- Experience with mass/energy balances, scale-up methodology, corrosive-service materials selection, and P&IDs.;
- Demonstrated experience writing SOPs, contributing to HAZOPs, and managing oxidiser-related emissions and waste streams.
- Strong experimental design, data analysis and technical reporting skills.
- Eligible to obtain and maintain an Australian Explosives Licence and Defence Security Clearance.

Desirable:

- Experience converting chloride, sodium/potassium brines into chlorate/perchlorate at lab or pilot scale.
- Familiarity with catalyst/packing materials for packed-bed DBD reactors or plasma-enhanced catalytic systems.
- Experience delivering pilot-scale or process-scale demonstrations.

Why Us?

- Competitive remuneration.
- Impactful work contributing to Australia’s sovereign defence capability.
- Rare prospect in a state-of-the-art energetic-materials manufacturing facility.
- Professional development and leadership growth pathways.
- Supportive, innovative engineering culture.
- Located near Victoria’s Bass Coast - enjoy regional and coastal living with city access.

Interested?

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📌 Senior Research Engineer / Scientist (Ammonium Perchlorate Production) (Melbourne)
🏢 DefendTex
📍 Melbourne