Process Engineering Senior

Senior Process Engineer - Capital Projects (Consolidated Separations Plant) Wheat Ridge, CO

We are on a mission to become a leading supplier of critical materials that enable the green energy and technology revolution. Our materials and technologies are required for the electric vehicle, green energy, consumer electronics, and defense industries, and our battery grade lithium and tech metals are needed for chipsets, semiconductors, and 5G.
We have a substantial interest in the Round Top, Heavy Rare Earth, Lithium and Critical Minerals deposit in West Texas. We have also developed the United States’ first rare earth and critical minerals processing facility and we own the only scalable, sintered neo-magnet manufacturing system in the Western Hemisphere. By developing this fully integrated, US-based “mine-to-magnet” critical mineral supply chain, we are poised to become the leading domestic supplier to these industries.

At USA Rare Earth, we are pioneers and problem solvers, technologists and team players. We are creative and solution-oriented, and we think outside the box to solve important problems. We know that a range of expertise and technologies is needed for success, and we work across sectors and alongside customers to deliver world-class solutions in sustainable ways.

Deliver Quality : We believe that top-tier quality leads to industry competitiveness and we hold ourselves to the highest quality standards. We move fast when executing, but safety, quality, and excellence always come first.

We put safety at the center of all we do, take accountability for our actions, incorporate sustainable practices in our processes and act with the financial best interest of our investors and consumers in mind.

We are seeking a Senior Process Engineer, Capital Projects to serve as the owner's representative interfacing with our EPCM contractor on our Consolidated Separations Plant project during FEL-3 Engineering through project execution. The Consolidated Downstream Separations Plant will produce high purity rare earth oxides from 3rd party and internal feedstocks. The successful candidate will ensure that the knowledge and direction from our internal process development SMEs is accurately captured, formally transmitted, and tracked through the EPCM's engineering deliverables.

Serve as the primary liaison between USA Rare Earth's process development team and the EPCM contractor, acting as the owner's representative to ensure alignment on technical deliverables, schedule, and design intent.
Lead structured review cycles for key engineering deliverables including Process Design Criteria (PDC), Block Flow Diagrams (BFD), Process Flow Diagrams (PFD), Piping & Instrumentation Diagrams (P&ID), and control philosophy documents. Liaise with external partners, including EPCMs, equipment manufacturers, engineering consultants, and regulatory agencies.
Coordinate with USA Rare Earth's internal subject matter experts across process development, chemistry, and piloting to capture technical input efficiently without disrupting ongoing R&D and pilot operations. Translate SME knowledge into formal engineering guidance for the EPCM.
Ensure that SME input is accurately reflected in final engineering deliverables. Contribute to process hazard analyses (PHAs) and ensure compliance with environmental and safety regulations.
Review EPCM-produced process equipment sizing, utility requirements, and equipment datasheets to ensure alignment with pilot-scale performance data and established design intent.
Develop a thorough understanding of the rare earth separation process from swarf feedstock through MREC processing to separated rare earth oxide production. Serve as the technical steward of the process design basis in coordination with the process development SMEs.
Support design and commissioning of pilot- and commercial-scale process systems, including test plans and performance verification.

Bachelor's degree in Chemical Engineering, Metallurgical Engineering, or a related field; 10–15 years of process engineering experience, with significant exposure to capital project delivery in the minerals processing, hydrometallurgy, or chemical processing industries.

• Demonstrated experience as an owner's representative or engineering lead interfacing with an EPCM or EPC contractor on a major capital project
• Strong working knowledge of engineering deliverables including PDC, BFD, PFD, P&ID, and control philosophy; Ability to synthesize complex process development data and SME input into clear, actionable technical guidance for an EPCM team.
• Collaborative team player who can engage effectively with both technical SMEs and project management stakeholders.
• Experience with FEL-2 or FEL-3 engineering execution on a minerals processing or chemical plant project.
• Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

Exposure will vary and include normal office noise, typical laboratory sounds (e.g., ventilation systems, equipment operation), manufacturing floor noise (e.g., machinery, forklifts), and construction site noise depending on project phase and location.
The reporting relationship may not reflect the most recent changes to the corporate reporting structure.

Department: Mining