Senior Process Engineer

Job Title: Senior Process Engineer

Job Description

You will lead the scale-up of our pilot project into a demonstration plant, laying the groundwork for future commercial facilities. This role involves translating R&D efforts into engineered processes, partnering with external engineering firms/EPCs, and ensuring safe, on-time construction and commissioning.

Responsibilities

• Lead the scale-up from lab/pilot to demonstration and commercial scale for rare-earth metallization processes.
• Own core process deliverables such as PFDs, P&IDs, mass & energy balances, control narratives, and operating envelopes.
• Translate internal research into detailed engineering packages for external partners, managing scope, interfaces, and change control.
• Direct custom equipment specification, vendor selection, FAT/SAT, and installation through third-party fabricators.
• Plan and run HAZOP/LOPA and safety reviews; implement safeguards and MOC.
• Coordinate with EPC contractors to ensure schedule, cost, quality, and safety targets are met through mechanical completion and startup.
• Develop commissioning plans, SOPs, and operator training; support ramp-to-rate and reliability growth.
• Optimize processes for yield, throughput, cost, environmental compliance, and uptime; instrument KPIs and drive continuous improvement.
• Navigate permitting and regulatory documentation in collaboration with EHS and external consultants.
• Anticipate risks and unblock issues rapidly in an agile, high-accountability environment.

Essential Skills

• Experience in process engineering, from lab/pilot to commercial scale.
• Typically 5+ years as a Process/Project Engineer in industrial plant design, construction, or operations (chemicals, metallurgical, electrochemical, or related).
• Demonstrated success scaling processes from lab/pilot to commercial scale.
• Experience managing and communicating effectively with engineering firms and EPC contractors.
• Strong command of PFDs, P&IDs, mass/energy balances, control strategies, HAZOP, and regulatory compliance.
• Proven track record delivering plants or major process units safely, on schedule, and on budget.
• Excellent cross-functional communication, documentation, and project leadership.

Work Environment

The position is based onsite in Alameda, and relocation options are available. The work environment is agile and high-accountability, focused on accelerating Western rare-earth production.

This is a Permanent position based out of Alameda, CA.

The pay range for this position is $150000.00 - $350000.00/yr.

Competitive base salaryComprehensive health, dental, and vision insuranceCompany-provided lunch dailyVisa sponsorship available if needed

This is a fully onsite position in Alameda,CA.

This position is anticipated to close on Apr 10, 2026.

Diversity, Equity & Inclusion

At Actalent, diversity and inclusion are a bridge towards the equity and success of our people. DE&I is embedded into our culture through:

• Hiring diverse talent
• Maintaining an inclusive environment through persistent self-reflection
• Building a culture of care, engagement, and recognition with clear outcomes
• Ensuring growth opportunities for our people

Actalent is an equal opportunity employer.

About Actalent

Actalent is a global leader in engineering and sciences services. For more than 40 years, we’ve helped visionary companies advance their goals. Headquartered in the United States, our teams span 150 offices across North America, EMEA, and APAC—with four delivery centers in India led by 1,000+ extraordinary employees who connect their passion with purpose every day.

Our Bangalore, Hyderabad, Pune, and Chennai delivery centers are hubs of engineering expertise, with core capabilities in mechanical and electrical engineering, systems and software, and manufacturing engineering. Our teams deliver work across multiple industries including transportation, consumer and industrial products, and life sciences. We serve more than 4,500 clients, including many Fortune 500 brands. Learn more about how we can work together at actalentservices.com.