Senior Process Engineer

Responsibilities

• Lead scale-up from lab/pilot to demonstration and commercial scale for rare-earth metallization processes.
• Own core process deliverables: PFDs, P&IDs, mass & energy balances, control narratives, and operating envelopes.
• Translate internal research into detailed engineering packages for external partners; manage scope, interfaces, and change control.
• Direct custom equipment specification, vendor selection, FAT/SAT, and installation through third-party fabricators.
• Plan and run HAZOP/LOPA and safety reviews; implement safeguards and MOC.
• Coordinate with EPC contractors to ensure schedule, cost, quality, and safety targets are met through mechanical completion and startup.
• Develop commissioning plans, SOPs, and operator training; support ramp-to-rate and reliability growth.
• Optimize processes for yield, throughput, cost, environmental compliance, and uptime; instrument KPIs and drive continuous improvement.
• Navigate permitting and regulatory documentation in collaboration with EHS and external consultants.
• Anticipate risks and unblock issues rapidly in an agile, high-accountability environment.
• What You Bring
• Required
• Typically 5+ years as a Process/Project Engineer in industrial plant design, construction, or operations (chemicals, metallurgical, electrochemical, or related).
• Demonstrated success scaling processes from lab/pilot to commercial scale.
• Experience managing and communicating effectively with engineering firms and EPC contractors.
• Strong command of PFDs, P&IDs, mass/energy balances, control strategies, HAZOP, and regulatory documentation.
• Track record delivering plants or major process units safely, on schedule, and on budget.
• Excellent cross-functional communication, documentation, and project leadership.
• Availability to start soon.
• Preferred
• Background in high-temperature processes, electrochemical cells, molten-salt systems, or rare-earth metallurgy.
• Familiarity with environmental/permitting frameworks for chemical/metallurgical facilities.
• Start-up/commissioning experience and hands-on time in operating plants.
• Working knowledge of CAD/CAE tools and data analysis for process performance.
• Compensation & Benefits
• Competitive base salary
• Comprehensive health, dental, and vision insurance
• Company-provided lunch daily
• Visa sponsorship available if needed

Benefits

Additional Information

Making the Metals Powering the World Solcoa exists to stabilize the western rare-earth metal supply chain-powering every fighter jet, EV, wind turbine, phone, and generator. We're among the very few companies outside China producing rare-earth metals-and the only one delivering a 100% U.S. supply of both light and heavy rare earths. Our carbon-zero process converts end-of-life magnets directly into metal, ready to accelerate energy independence and secure one of the world's most vital resources. We are a lean, well-funded team rapidly accelerating Western rare-earth production. We're building a world-class team to solve this crisis. The Role - Senior Process Engineer You'll lead the scale-up of our pilot into a demonstration plant, laying the groundwork for follow-on commercial facilities. You'll translate R&D into engineered processes, partner with external engineering firms/EPCs, and drive safe, on-time construction and commissioning.

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