ASTRAEA Process Engineer: Scale-Up & Tech Transfer Lead

Alcoa Australia; New Kensington (Westmoreland County); On-site; USD 120,000 - 180,000; Full time

Benefits offered by this job

Stock-based compensation awards (3‑yr.

HSA employer contribution

401(k) employer match up to 6%

Non-qualified deferred compensation

12 paid holidays

15 days paid vacation

Employee Assistance Program (EAP)

Job summary

Alcoa in New Kensington, PA, seeks a Senior Process Engineer to lead the ASTRAEA electrolysis tech development from lab testing to pilot and commercial deployment. You will ensure safe, reliable operation, drive process optimization, and mentor teams across ATC and pilot facilities.

Travel ~30% to align, train, and commission across global sites, collaborating with engineering partners, suppliers, and plant personnel to deliver scalable solutions and regulatory compliance.

Qualifications

• Bachelor’s Degree in a STEM discipline.
• 7+ years of experience in process engineering within electrolysis, metals, manufacturing, chemical processing, or other heavy industrial environments.
• Proven experience developing, scaling, and implementing technologies from laboratory or pilot-stage testing through startup, commissioning, and commercial operation.
• Strong expertise in process optimization, troubleshooting, root cause analysis, process controls, data analysis, and continuous improvement methodologies.

Responsibilities

• Lead development, optimization, and scale-up of ASTRAEA electrolysis technology from laboratory testing through pilot and commercial deployment.
• Provide technical support of process performance, including troubleshooting, root cause analysis, and continuous improvement initiatives.
• Establish operating standards, control strategies, and technology packages to support successful scale-up and commercialization.
• Lead technology transfer activities between research, pilot, and operating facilities, ensuring commissioning and startup readiness.
• Mentor engineers and operations teams while providing technical leadership for pilot operations and future deployments.

Skills

Process optimization

Root cause analysis

Data analysis

Troubleshooting

Cross-functional collaboration

Education

Bachelor’s Degree in STEM

Master’s Degree (preferred)

Professional Engineer license (preferred)

Job description

Alcoa in New Kensington, PA, seeks a Senior Process Engineer to lead the ASTRAEA electrolysis tech development from lab testing to pilot and commercial deployment. You will ensure safe, reliable operation, drive process optimization, and mentor teams across ATC and pilot facilities.

Travel ~30% to align, train, and commission across global sites, collaborating with engineering partners, suppliers, and plant personnel to deliver scalable solutions and regulatory compliance.