Senior Process Engineer
Job Summary
We are seeking a Senior Process Engineer to lead the scale-up and commissioning of a new 500 ton per year rare earth metallization plant. This role owns final detailed engineering, vendor coordination, and driving the facility from current state through construction, startup, and ramp to full production rates.
You will join a lean, high-accountability team focused on reshoring critical metal production using novel, cleaner technologies. This is a hands-on leadership position for an engineer who has successfully taken industrial plants from design through commissioning end-to-end.
Essential Functions
- Finalize detailed engineering for vacuum induction furnace and associated plant systems
- Manage vendor relationships including equipment specification, selection, FAT, SAT, and installation
- Coordinate plant site modifications including structural changes, foundations, and utility tie-ins for power, water, gas, and compressed air
- Own and maintain core process documentation such as PFDs, P&IDs, mass and energy balances, and control narratives
- Develop comprehensive commissioning plans, standard operating procedures, and operator training programs
- Lead the plant through construction, startup, and production ramp-up phases on schedule and within budget
Required Qualifications
- 6-10 years of experience in process or project engineering for industrial plant design, construction, and commissioning
- Proven success leading a plant or facility through commissioning from detailed engineering to full operation
- Experience scaling processes from pilot or lab scale to commercial production
- Strong background in high-temperature materials processing and furnace operations
- Hands-on experience developing and managing PFDs, P&IDs, mass and energy balances, and HAZOP studies
- Demonstrated vendor management skills including equipment specification, FAT/SAT, and installation oversight
- Bachelor's degree in chemical engineering, metallurgical engineering, or related field
- First-principles thinker with ability to operate effectively in fast-paced, high-accountability environments
Preferred Qualifications
- Prior experience at innovative technology or advanced materials companies
- Startup or scale-up environment background
- Evidence of exceptional academic or professional achievement
- Experience with vacuum induction melting systems
Technical Skills
- PFDs and P&IDs
- Mass and energy balances
- HAZOP and LOPA studies
- High temperature furnaces
- Vacuum induction systems
- CAD and CAE tools
- Vendor and contractor management
- Process safety and commissioning protocols
- Control system narratives
Education & Certifications
Bachelor's degree in Chemical Engineering, Metallurgical Engineering, or a closely related engineering discipline is required. Advanced degree preferred but not mandatory.
Compensation & Benefits
Base salary range is $135,000 to $350,000 per year depending on experience and qualifications. This is a full-time, on-site position based in the San Francisco Bay Area.