Senior Process Engineer; Mineral & Metal Refining

We are seeking a highly motivated and experienced Senior Process Engineer to lead scale up from pilot to commercial operations supporting the separation and refining of defense critical mineral sand rare earth elements. This position plays a key role in scaling current operations into robust, continuous, and commercially viable processes for high-purity oxide production. The Senior Process Engineer will oversee plant design, operation, troubleshooting, and optimization, ensuring safety, efficiency, and data integrity while collaborating with R&D, analytical, and production teams.

• Lead the translation of pilot/lab-scale processes into commercially viable manufacturing operations, including mass and energy balance modeling
• Develop and optimize process flow diagrams (PFDs), piping & instrumentation diagrams (P&IDs), and equipment specifications for scaled systems
• Identify and resolve scale-up challenges related to heat transfer, mass transfer, mixing, and reaction kinetics
• Own the technical basis for process design packages and engineering deliverables
• Collaborate with equipment vendors and engineering contractors to evaluate and specify commercial-scale equipment
• Conduct hazard reviews (HAZOP, FMEA) and ensure designs meet safety and regulatory requirements
• Establish process control strategies, operating windows, and critical process parameters (CPPs)
• Drive continuous improvement initiatives to improve yield, throughput, and cost of goods
• Partner with R&D, operations, supply chain, and quality to align process design with product requirements and business goals
• Support capital project execution (from FEED through commissioning and startup)

• Bachelor’s degree in Chemical Engineering, Metallurgical Engineering, Materials Science, or related field.
• Minimum 7+ years of hands‑on experience in pilot or production operations for hydrometallurgical, chemical, or materials processes.
• Strong practical understanding of unit operations, process control, and data‑driven optimization.
• Proven track record of scaling up laboratory processes to pilot or commercial level.
• Excellent leadership, troubleshooting, and cross‑disciplinary communication skills.

• M.S. degree or Professional Engineer (P.E.) certification.
• Experience in rare‑earth, lithium, or critical‑metal refining.
• Familiarity with chromatography‑based or solvent‑free separation technologies.
• Working knowledge of mass balance modeling, Aspen Plus, or similar process simulation tools.
• Demonstrated ability to lead commissioning and performance testing campaigns.
• Primarily based in a pilot‑scale process facility, involving operation of chemical process equipment.
• Requires frequent collaboration with R&D, analytical, and production staff.
• Involves handling of acids, bases, and metal‑bearing solutions; PPE and EHS compliance are mandatory.
• Occasional travel to partner sites or commercial facilities for process trials and technology transfer.
• Salary range:
  Negotiable
• Comprehensive medical, dental, and vision coverage
• Professional development and leadership advancement opportunities
• Opportunity to contribute to the commercialization of sustainable, solvent‑free refining technologies for the critical materials industry