Senior Process Engineer, Mechanical Engineering

We are seeking a highly skilled and motivated Senior Process Engineer to lead the planning, design, and execution of complex industrial process systems for mining, minerals processing, material handling, and heavy industrial facilities. This role is responsible for developing process solutions that improve operational performance, safety, reliability, and efficiency while collaborating closely with multidisciplinary engineering teams and clients.

The ideal candidate possesses extensive experience designing and evaluating industrial process facilities, including process piping systems, slurry transport systems, bulk material handling equipment, pumping systems, and plant utility infrastructure. The Senior Process Engineer serves as a technical leader and trusted advisor throughout project planning, design, construction, and commissioning activities.

Under our “Seller-Doer” approach to business development, you will collaborate with the Vice President of Mining, Market Managers, and other Group Managers to develop and implement a marketing plan, track prospective business opportunities, make strategic decisions for project pursuits, lead proposal development efforts, and represent TKDA at project interviews. You will also be expected to cultivate and maintain relations with key decision makers and representatives of current and prospective clients by attending local and regional conferences and networking events.

\n Location and Work Arrangement

Our preference is for this position to be based out of Duluth, MN or Bloomington, MN; however, we will consider candidates residing within greater Minnesota and Wisconsin if experience and qualifications align with this position and market development initiatives. TKDA offers flexible hybrid work arrangements, with employees typically working three days in the office and two days remotely, in alignment with business needs. Regular travel to TKDA offices, project locations, industry-specific conferences will be required along with team events for remote candidates to foster collaboration, strengthen relationships, and support project success.

What You'll Do

Process Engineering & Design

Lead process engineering efforts for mining, mineral processing, aggregate, metals, and heavy industrial projects.

• Develop process flow diagrams (PFDs), piping and instrumentation diagrams (P&IDs), mass and energy balances, and process design criteria.
• Design and specify industrial process systems including: process piping systems, slurry transport systems, pumping and dewatering systems, bulk solids handling systems, conveying systems, ore handling and crushing facilities, material storage and transfer systems, dust collection and ventilation systems, water treatment and process water systems, or utility systems supporting industrial operations.
• Perform hydraulic calculations, equipment sizing, process analyses, and system evaluations.
• Develop equipment specifications and technical procurement packages for pumps, conveyors, tanks, crushers, screens, piping systems, and related process equipment.
• Evaluate facility bottlenecks and recommend process improvements that enhance safety, reliability, throughput, and operational efficiency.

Project Leadership

Serve as Lead Process Engineer on multidisciplinary industrial projects.

• Develop project scope, budgets, schedules, and engineering work plans.
• Coordinate activities with mechanical, structural, electrical, instrumentation, civil, and environmental disciplines.
• Provide technical oversight and quality review of engineering deliverables.
• Support project managers in managing technical scope and client expectations.
• Participate in design reviews, hazard assessments, constructability reviews, and operational readiness activities.

Client Management & Business Development

• Work directly with clients to understand operational challenges and identify engineering solutions.
• Participate in client meetings, site visits, and facility assessments.
• Support proposal development, scope definition, and fee estimates.
• Assist in the development of long-term client relationships and identification of future opportunities.
• Represent the firm at client presentations, industry conferences, and professional organizations.

Technical Leadership

• Mentor junior and mid-level engineers.
• Establish engineering standards, design practices, and quality procedures.
• Contribute to process engineering best practices across the organization.
• Promote innovation, continuous improvement, and knowledge sharing within the engineering team.

Required Qualifications

• Bachelor's degree in chemical engineering, mechanical engineering, metallurgical engineering, mining engineering, or related engineering discipline.
• Experience serving as a lead engineer on multidisciplinary industrial projects.
• Strong understanding of: process design methodologies, hydraulic systems, process piping design, industrial pumping systems, bulk solids handling, industrial equipment selection, and process safety principles.
• Experience with PFDs, P&IDs, process calculations, and engineering specifications.
• Excellent communication, leadership, and project coordination skills.
• Ability to travel periodically to active industrial facilities and project sites.

Advantageous Qualifications

• Professional Engineer (PE) with twelve or more years of progressive engineering experience in mining, mineral processing, bulk materials handling, industrial manufacturing, or similar heavy industrial environments.
• Experience designing facilities for: mining and mineral processing, aggregate operations, metals processing, cement manufacturing, industrial manufacturing, or material handling and transportation systems.
• Experience with slurry pipelines and abrasive process systems.
• Knowledge of process simulation and modeling software.
• Familiarity with industrial control systems and instrumentation.
• Experience supporting commissioning and startup activities.
• Previous consulting engineering experience.
• Leadership experience managing engineering teams or large project scopes.

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$110,500 - $155,000 a year

The listed salary range reflects only the starting base pay range for candidates with 10-20 years of related experience in our Duluth, Minnesota office. Compensation is determined based on technical skills, experience level, and qualifications. Candidates with more experience or different compensation expectations are encouraged to apply. All candidates are evaluated on the full scope of what they bring to the role. - The base compensation range for this position out of our Bloomington, MN would be $116,500 - 164,500.

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Join Our 100% Employee-Owned Firm

At our company, every employee is an owner. From the front desk to the corner office, every one of our 430+ professionals thrive on collaboration and holistic development. Our success is collective, and so are the rewards.

Comprehensive Benefits

Health Benefits: Enjoy medical, dental, vision, and life insurance from day one

Annual Incentive Plan: Eligible for discretionary bonuses

HSA Contributions: Receive monthly employer contributions if you choose an HSA-eligible plan

401(k) Match: Get employer matching on your 401(k) deferrals

ESOP: Benefit from our Employee Stock Ownership Plan, funded entirely by company profits

Paid Time Off: Accrue PTO based on your professional experience and enjoy eight paid holidays per year

Upon receiving a formal offer, you will get a personalized Total Compensation Overview (TCO) to see how everything adds up and what it looks like to be part of our community.

TKDA is committed to creating a diverse environment and is proud to be an equal opportunity employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, national origin, disability, or veteran status, gender identity, or any other characteristics protected by law. We celebrate diversity and are committed to creating an inclusive environment for all employees, all applicants are strongly encouraged to apply.

All applicants must be authorized to work in the United States for any employer without current or future visa sponsorship needs or requirements. TKDA does not sponsor any type of employment visas, including but not limited to H‑1B, F‑1 OPT/CPT, TN, or other work authorization programs.

*Pre-Employment Screening*

Upon acceptance of a conditional offer of employment, the selected candidate will be required to complete a standard pre-employment background screening, which consists of Social Security verification, educational verification, review of criminal convictions, and driving history.

*Notice to Recruiters and Placement Agencies*

TKDA will not accept unsolicited resumes from recruiters or placement agencies unless a service agreement is in place. In the event TKDA receives an unsolicited resume without a service agreement in place, TKDA will not be obligated to pay a service fee of any amount nor will TKDA be held liable to terms or conditions under any agreement of any kind that has not been authorized in writing by a TKDA officer.