Senior Process Engineer – Hydrometallurgy

Senior Process Engineer – Hydrometallurgy

We are seeking an experienced and dedicated Senior Process Engineer to lead the development and optimization of our hydrometallurgical processes focused on synthesizing High-Purity Alumina (HPA) from halloysite clay
. This is a critical role requiring strong expertise in chemical process design, acid leaching, purification techniques, and crystallization for achieving ultra-high material purity.

As a Senior Process Engineer specializing in HPA synthesis, your responsibilities will focus on the end-to-end hydrometallurgical flowsheet:

• Process Design and Optimization: Lead the design, development, and optimization of the entire HPA hydrometallurgical flowsheet, including acid leaching, impurity removal (purification), and final aluminum salt crystallization steps.
• Leaching Kinetics: Conduct detailed analysis and modeling of the leaching process for clay to maximize aluminum extraction while minimizing the dissolution of contaminants.
• Purification Strategy: Develop and optimize advanced purification unit operations (e.g., solvent extraction, ion exchange, or precipitation) required to remove trace impurities down to the ppm levels necessary for HPA (4N/5N purity).
• Crystallization and Calcination: Optimize the crystallization parameters (temperature, concentration, residence time) for the final aluminum precursor salt, and define the subsequent calcination requirements to yield high-quality HPA powder.
• Scale-Up and Commissioning: Drive the process scale-up from pilot to commercial demonstration, including PFD/P&t, equipment specification, commissioning support, and operational readiness.
• Troubleshooting: Serve as the primary technical expert for diagnosing and resolving complex operational issues related to corrosion, material stability, impurity buildup, and yield loss within the chemical plant environment.
• Safety and Compliance: Ensure all hydrometallurgical processes and plant designs strictly adhere to safety, health, and environmental standards.
• Technical Reporting: Prepare comprehensive technical reports, economic evaluations, and process manuals detailing methodology, optimization results, and intellectual property development.

• Bachelor’s degree (or higher) in Chemical Engineering, Metallurgical Engineering, or a closely related field.
• Minimum of 5+ years of progressive experience in process engineering, with at least 4 years of direct, hands-on work experience in a chemical processing plant or metals refining operation (e.g., critical minerals).
• Strong theoretical and practical background in hydrometallurgy, particularly acid leaching and advanced purification techniques (Solvent Extraction, Ion Exchange, etc.).
  • Demonstrated knowledge of chemical crystallization processes and powder characteristics derived from various processes.
• Specific experience or deep familiarity with the processing of clays, aluminosilicates, or geological minerals is highly desirable. Experience with high-purity material production is a significant asset.
• Proficiency in process simulation software (e.g., Aspen Plus, HSC Chemistry) and advanced data analysis.
• Exceptional problem-solving skills, ability to manage complex projects, and demonstrated success in process scale-up and optimization.
• This role requires to be on-site at our Provo, UT facility.

• Competitive compensation package.
• Full company benefits, including health, vision, and dental insurance.
• Additional benefits such as retirement plans, paid time off, and opportunities for professional development.