Process Engineer

Process Engineer

The Process Engineer is the on-site technical resource for process engineering at the Lancaster facility, providing hands-on Operations support, driving continuous process improvement, and leading small-capital project execution. This role partners closely with Operations, Maintenance, EHS, and Capital Projects to improve process reliability, safety, and throughput across the site's battery recycling operations. Core focus areas include:

• Providing on-site troubleshooting and technical support to Operations to resolve process upsets and improve equipment reliability
• Identifying, evaluating, and implementing continuous process improvement opportunities across safety, quality, throughput, and cost
• Developing and executing small capital projects, from scope and justification through commissioning and start-up
• Implementing, maintaining, and continuously improving process safety systems in alignment with PSM and RMP requirements

Key Responsibilities:

• Identify and lead the execution of continuous improvement projects that increase yield, reliability, and cost efficiency across the process
• Lead troubleshooting efforts and provide hands-on technical support to Operations for process upsets, equipment issues, and process control
• Serve as the plant's local resource for capital project development, process design, and execution, partnering with corporate Engineering as needed
• Support the development and optimization of recovery processes for nickel, cobalt, lithium, and other metals and materials recovered from batteries
• Perform root cause analysis on process deviations, equipment failures, and quality or safety incidents, and drive corrective and preventive actions
• Collect, analyze, and report process and production KPIs (yield, uptime, throughput, and quality) to support data-driven decision-making
• Participate in and support additional site PSM elements, including management of change (MOC), incident investigation, document management, employee training, and pre-start-up safety reviews (PSSR)
• Develop and maintain P&IDs, process flow diagrams, and equipment specifications to keep engineering documentation current and accurate
• Develop and execute time and motion studies to streamline battery disassembly, tear-down, and material staging activities
• Support standard operating procedure (SOP), training, commissioning, and maintenance plan creation for newly installed process equipment
• Partner with Maintenance to define equipment reliability strategies, preventive maintenance schedules, and critical spare parts requirements
• Coordinate with Quality to investigate and resolve process-related deviations and support product specification compliance
• Support Health, Safety and Environmental (HS&E) improvement initiatives and compliance, including Process Safety Management (PSM), EPA Risk Management Plan (RMP), and broader environmental requirements (permits, wastewater, air emissions, waste characterization)
• Evaluate and support scale-up of new or emerging process technologies from pilot through full production
• All other duties as assigned

Qualifications:

Required:

• Bachelor of Science degree in Engineering (Chemical Engineering strongly preferred)
• 3-5 years of process engineering experience in mining, chemical processing, battery materials, or a related industrial manufacturing environment
• Working knowledge of process design, unit operations, and process control fundamentals
• Demonstrated ability to troubleshoot process and equipment issues using structured root cause analysis techniques (5 Why, fishbone, FMEA)
• Familiarity with P&IDs, process flow diagrams, and technical engineering drawings
• Working knowledge of Process Safety Management (PSM) and EPA Risk Management Plan (RMP) requirements
• Proficiency with Microsoft Excel and other data analysis tools to track and report process performance
• Self-driven with the ability to work independently and manage multiple priorities in a fast-paced plant environment
• Strong written and verbal communication skills, with the ability to convey technical information to cross-functional audiences
• TRAVEL: Infrequent

Preferred:

• Technical experience in solids handling, milling, and solid/liquid separation
• Experience in hydrometallurgical, extractive metallurgy, or battery recycling processes
• Six Sigma / LEAN certification (Green Belt or higher) with demonstrated continuous improvement project experience
• Experience with capital project cost estimating, scope development, and contractor/vendor management
• Familiarity with Power BI, Minitab, or similar statistical and data visualization tools
• Experience supporting environmental compliance activities (air permits, wastewater discharge, hazardous waste management)

Physical Requirements:

• Standing/Walking: Sometimes
• Sitting: Sometimes
• Lifting/Carrying <20 lbs: Sometimes
• Lifting/Carrying 20-50 lbs: Sometimes
• Lifting/Carrying >50 lbs: Never
• Pushing/Pulling: Sometimes
• Climbing: Stairs
• Stopping/Bending: Sometimes
• Reaching above shoulder: Sometimes
• Repeating motions that may include wrists, hands, and/or fingers: Most Times
• Operate Motor Vehicle: Sometimes
• Operate Manual Equipment: Never
• Operate machinery/power tools: Never

Worksite Conditions:

• Weather Exposure: Never
• Temperature Extremes: Never
• Noise: Sometimes
• Odors: Sometimes
• Dust or Mist: Sometimes
• Fumes or Vapors: Sometimes
• Chemicals <1 liter: Sometimes
• Chemicals drummed: Sometimes
• Chemicals bulk tank: Never
• Respirator: Never
• Personal Protective Clothing: Sometimes
• Personal Protective Equipment: Sometimes

Benefits:

• Medical, Dental, & Vision
• HSA/HRA/FSA
• Employee Assistance Program (EAP)
• 401(k) Retirement Savings Plan with employer match
• Wellness programs and incentives
• Life & Disability, Accident, Critical Illness, & Hospital Indemnity
• Paid Time Off
• 80 hours of paid company holidays