Process Engineer - Kiln Area

Company Overview:

We are the only U.S. company with a fully integrated rare earth supply chain—from mining and refining to advanced metal and magnet manufacturing. Our products include both the critical materials used to make permanent magnets and the finished magnets themselves—enabling next-generation technologies in robotics, automation, aerospace, transportation, defense, and energy systems. These materials are the foundation of physical AI—the convergence of computation, movement, and control.

We hire ambitious, mission-driven people who want to tackle complex challenges and shape the future of strategic industries. Our culture is rooted in teamwork, resiliency, and integrity, with a deep commitment to operational excellence and national purpose. MP is rapidly evolving from a materials producer into a leading U.S. manufacturer—and our people are driving that transformation.

There are four levels of process engineers in the Process Technology and Engineering Department, I, II, and Senior, all reporting to the area Lead Process Engineer. MP Materials is currently looking for levels I, II, and Senior Process Engineers. They will collaborate with other plant engineering staff, supervisors, operators, and management in the design, implementation, startup, and optimization of various new and existing unit operations, monitor daily process and equipment control parameters, and adjust as necessary to ensure safe production, quality, efficiency, and uninterrupted operation.

Process engineers also investigate process upsets, develop conceptual engineering & initial capital project scopes, and make recommendations to improve process safety, quality, efficiency, and profitability.

• Guide daily plant operations using engineering best practices.
• Create and review Standard Operating Procedures (SOP) and process log sheets for new and existing processes; work with area trainers to effectively communicate materials to the operations group.
• Create and maintain PFDs, P&IDs, mechanical and layout drawings, process control procedures, and design basis documentation.
• Provide technical training to operations personnel.
• Promote process safety and manage risk through appropriate engineering and administrative controls.
• Track and present key performance indicators (KPIs); update operating setpoints, strategy, and procedures based on KPIs for continual process improvement.
• Use statistical process control programs and techniques to analyze process KPIs.
• Identify and create preliminary technical scope packages for small capital projects; participate in the capital project lifecycle to ensure successful design and implementation.
• Develop and communicate cost, benefits, and risk information on new process changes.
• Participate in the Management of Change process, creating and executing MOC projects.
• Participate in environmental, health, and safety initiatives, and ISO 9001.
• Collaborate with the project management team, purchasing department, vendors, maintenance, contractors, operators, and other team members as needed to maintain safe, reliable operations.
• Complete any other tasks as needed or as directed by management.

• Bachelor’s degree in chemical engineering.
• Process Engineer I: 0-3 years of work experience in a chemical plant, mining, petroleum, or a similar heavy industrial setting.
• Process Engineer II: 3-6 years of work experience in a chemical plant, mining, petroleum, or a similar heavy industrial setting.
• Senior Process Engineer: 6+ years of work experience in a chemical plant, mining, petroleum, or a similar heavy industrial setting.
• Valid Drivers License to drive company vehicles on and off property.

• Prior experience with mills, flotation circuits, thickeners/clarifiers, slurry systems, dry solids handling, dissolution reactors, precipitation reactors, filter press, belt filter, and other various filtration technology, centrifugal and positive displacement pumps, heat exchangers, cooling towers, instrumentation and process control automation, steam & power generation, reverse osmosis, water treatment, evaporators, crystallizers, centrifuges.
• Excellent communication skills, verbal and written.
• Ability to complete a task with appropriate coaching and minimal supervision.
• Ability to create, read, and modify PFD’s and P&’s, material & energy balances.
• High proficiency in Microsoft Office (Word, Excel, PowerPoint), statistical software, and PI Process Book.
• Ability to travel as needed (