R&D Engineer, Rare Earth Processing & Scale-Up

Usare Industria E Comercio De Utilidades; Wheat Ridge (CO); On-site; USD 85,000 - 125,000; Full time

Job summary

USA Rare Earth is seeking an R&D Engineer to advance extraction, separation, and purification of rare earths from primary and recycled feedstocks. The role bridges lab research and pilot plant operations to move processes toward commercial readiness.

You will design experiments, translate bench-scale to pilot-scale, and collaborate across teams to optimize recovery, efficiency, and product quality while upholding safety standards and documentation practices.

Qualifications

• Bachelor’s degree in Chemical, Metallurgical, or Materials Engineering (advanced degree a plus).
• 3–7 years of experience in hydrometallurgy, chemical processing, or process R&D.
• Experience with pilot plant operations and process scale-up.
• Familiarity with rare earth separation techniques (e.g., solvent extraction, precipitation) preferred.
• Strong data analysis, problem-solving, and process troubleshooting skills.
• Working knowledge of PFDs/P&IDs and process control systems (SCADA/DCS) is a plus.

Responsibilities

• Design and execute experiments for rare earth leaching, solvent extraction, and purification.
• Translate bench-scale work into pilot-scale operations, supporting scale-up and process optimization.
• Operate and support pilot plant systems, including test planning, data collection, and troubleshooting.
• Perform mass balances and analyze process data to improve recoveries, efficiency, and product quality.
• Develop technical documentation (SOPs, PFDs, test reports) to support pilot operations and scale-up.
• Collaborate with engineering and operations teams to advance process design and commercialization.
• Support safety programs, including PHAs and compliance with environmental and operational standards.
• Coordinate with external partners (EPCMs, vendors, labs) as needed.

Skills

Hydrometallurgy

Pilot Plant Operations

Process Scale-Up

Rare Earth Separation

Data Analysis

SCADA/DCS

PFDs/P&IDs

Education

Bachelor’s degree in Chemical/Metallurgical/Materials Engineering

Advanced degree (preferred)

Job description

USA Rare Earth is seeking an R&D Engineer to advance extraction, separation, and purification of rare earths from primary and recycled feedstocks. The role bridges lab research and pilot plant operations to move processes toward commercial readiness.

You will design experiments, translate bench-scale to pilot-scale, and collaborate across teams to optimize recovery, efficiency, and product quality while upholding safety standards and documentation practices.