Senior Process Engineer - Capital Projects (Consolidated Separations Plant)

Job Summary

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 3^rd 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.

Key Responsibilities

• 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. Consolidate, prioritize, and formally transmit SME comments to the EPCM. Track disposition of all comments through resolution. 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.
• Participate in and lead internal design reviews, HAZOP/PHA sessions, and constructability reviews on behalf of the owner. 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.

Qualifications

• Bachelor's degree in Chemical Engineering, Metallurgical Engineering, or a related field; advanced degree a plus.
• 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; experience managing formal comment review and disposition cycles.
• Ability to synthesize complex process development data and SME input into clear, actionable technical guidance for an EPCM team.
• Experience participating in or leading PHAs, HAZOPs, and design reviews.
• 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.
• Understanding of rare earth processing chemistry or secondary feedstock (scrap/swarf) processing is a plus.

Physical Demands

The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

Specific vision abilities required by this job include close vision and distance vision. While performing the duties of this Job, the employee is regularly required to walk, stand, move, sit, carry, bend, kneel, reach, push, pull, lift, use hands and fingers, handle, or feel and talk and hear. May be required to lift and move boxes or packages not exceeding 20 pounds in weight. Some work stress inherent to the position and extended work hours may be required. 

Work Environment:
The work environment will be a mix of a typical office environment, laboratory space, and construction site. 

Noise level:

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 above statements are intended to describe the general nature and level of work being performed by people assigned to this job. They are not intended to be an exhaustive list of all responsibilities, duties, skills required of personnel so classified. The reporting relationship may not reflect the most recent changes to the corporate reporting structure.

USA Rare Earth proudly supports Equal Employment Opportunities

USA Rare Earth's policy is to provide equal employment opportunities to all applicants and will provide reasonable accommodations according to applicable federal, state, and/or local laws.

For assistance applying for employment through this site due to disability, please contact Human Resources,

ht@usare.com