Mechanical Engineer - Thermal Analyst

Mechanical Engineer - Thermal Analyst

We are seeking a Thermal Analyst to support the design, analysis, and documentation of KP-FHR reactor structures, systems, and components from a thermal-fluids and heat-transfer standpoint.

In this role, you will:

• Develop thermal and thermal-hydraulic models for KP-FHR components and systems.
• Generate high-quality temperature fields, heat loads, and thermal boundary conditions that directly feed into structural integrity evaluations performed under ASME Section III, Division 5.
• Work side-by-side with structural integrity engineers to deliver integrated thermo-mechanical design-by-analysis for high-temperature metallic and graphite components.

This is a hands-on, analysis-focused position for an engineer who enjoys fluid mechanics, heat transfer, and first-principles modeling, and who wants to see their work directly influence high-consequence design decisions in a first-of-a-kind advanced reactor.

Responsibilities

Develop and execute thermal and thermal-hydraulic analyses for KP-FHR reactor structures and components (vessels, internals, core supports, piping, and auxiliary systems).

Build and maintain steady-state and transient thermal models (conduction, convection, radiation, conjugate heat transfer) using a combination of modeling paradigms (low/high fidelity).

Define thermal load cases and boundary conditions consistent with plant operating modes, transients, and test conditions; document the assumptions and linkages to plant-level process and safety analyses.

Collaborate closely with structural integrity / FEA engineers to:

• Provide temperature distributions and thermal loads as inputs to structural design-by-analysis.
• Iterate on design details to achieve acceptable combined thermo-mechanical margins.
• Ensure consistency between thermal models, structural models, and ASME code load combinations.

Use first-principles reasoning and simplified models (hand calculations, 1D conduction estimates, correlations, scaling arguments) to scope problems, cross-check CFD/system results, and communicate key physics.

Support development and evaluation of high-temperature fluid systems (e.g., molten fluoride salt loops, high-temperature gas systems, or auxiliary cooling circuits) by providing heat-transfer and temperature predictions to system designers.

Work with methods, materials, core design, and safety analysis teams to incorporate material properties, hot-spot limits, and safety criteria into thermal models and to propagate uncertainties where appropriate.

Develop and maintain high-quality calculation packages, technical memos, and design reports that clearly present methods, input data, model validation/verification basis, key results, uncertainties, and code-compliance conclusions for internal stakeholders and potential regulatory submittals.

Perform other duties as assigned in support of KP-FHR design, testing, and deployment.

Qualifications

Bachelor’s degree in Mechanical, Nuclear, Chemical, Aerospace Engineering, or a closely related field; advanced degree (M.S. or Ph.D.) in thermal-fluids, heat transfer, or a related area preferred.

Typically 3-7+ years of relevant experience in thermal analysis, thermal-fluids, or thermal-hydraulics for safety-critical or complex systems (nuclear, power, aerospace, process/chemical, or similar).

Strong foundation in heat transfer and fluid mechanics (conduction, convection, radiation, phase-change where applicable) and in applying correlations and dimensionless analysis to engineering problems.

Hands-on experience with one or more of the following:

• Thermal network / system analysis tools (or equivalent in-house methods).
• CFD tools for thermal-hydraulic analysis (e.g., STAR-CCM+, Fluent, or similar), including conjugate heat transfer.
• Porous-media / subchannel models for core or packed-bed analysis is a plus.

Experience interfacing with structural FEA: providing thermal loads and fields to structural analysts, understanding how temperature distributions drive thermal stresses, and iterating to achieve acceptable thermo-mechanical margins.

Familiarity with codes and standards (e.g., ASME BPVC) and how thermal loads feed into Section III, Division 5 design-by-analysis is highly desirable.

Demonstrated experience preparing formal calculation packages and technical documentation suitable for internal quality programs and potential regulatory use.

Familiarity with quality and configuration-management practices (e.g., working under NQA-1 or ISO 9001-like quality programs) is highly desirable.

Proficiency with scripting and data analysis tools (e.g., Python, MATLAB) for model setup, automation, and post-processing is a plus.

Knowledge, Skills & Abilities

First-principles and simplification mindset: ability to break complex thermal-hydraulic problems into transparent, tractable models and use them to guide higher-fidelity simulations.

Strong analytical skills and engineering judgment, especially when working with incomplete or uncertain input data in a first-of-a-kind advanced reactor.

High attention to detail and accuracy in model setup, material property selection, and data handling; takes pride in clean, review-ready work products.

Excellent written and verbal communication skills, including the ability to explain assumptions, limitations, and key sensitivities to both specialists and broader project stakeholders.

Demonstrated ability to work effectively in a multi-disciplinary, highly collaborative environment, including frequent interaction with structural, process, testing, and systems analysis teams.

Proactive, self-driven, and comfortable operating in a fast-moving, high-expectation environment.

Physical Demands & Work Environment

Ability to remain in a stationary position (sitting or standing) for extended periods while performing modeling and documentation work.

Ability to move within office, lab, and test environments, including occasional visits to test loops, experimental rigs, or fabrication areas, and to wear appropriate PPE (e.g., safety glasses, gloves, safety shoes) when required.

Work is primarily performed in a high-concentration office/technical environment, with occasional exposure to noisy or industrial settings during testing and system walk-downs.