Senior Process Engineer

Making the Metals Powering the World Solcoa is building the next generation of American metalmaking, starting with rare earths — the metals of power and motion. We've developed a new chemistry that converts rare earth oxides into high-purity metals — the materials inside every EV, fighter jet, wind turbine, and data center — cleaner, cheaper, and faster than any conventional process. Now we're scaling it to thousands of tonnes of annual production.

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.

What You’ll Do

• 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