Senior Process Engineer

USA Rare Earth, Inc. (Nasdaq: USAR); Colorado; Hybrid; USD 120,000 - 180,000; Full time

Job summary

USA Rare Earth, Inc. is seeking a Senior Process Engineer - Capital Projects to serve as the owner's representative with the EPCM contractor on the Round Top Rare Earth Project.

You will ensure SME knowledge is captured and transmitted through engineering deliverables during DFS and project execution. The role requires 10–15 years in process engineering with capital project delivery, strong PDC/BFD/PFD/P&ID expertise, and prior EPCM interfacing experience.

Qualifications

• Bachelor's degree in Chemical Engineering, Metallurgical Engineering, or related field is required.
• 10–15 years of process engineering with capital project delivery experience.
• Experience as owner's representative or engineering lead interfacing with EPCM on major capital projects.
• Strong knowledge of PDC, BFD, PFD, P&ID and control philosophy; experience in comment review cycles.
• Ability to translate SME input into actionable guidance for EPCM teams.
• Experience with PHAs, HAZOPs and design reviews.
• FEL‑2 or FEL‑3 execution experience on minerals processing or chemical plants is preferred.
• Knowledge of rare earth processing chemistry or secondary feedstock processing is a plus.

Responsibilities

• Serve as liaison between USA Rare Earth's process development team and the EPCM contractor to ensure alignment on technical deliverables, schedule, and design intent.
• Lead structured reviews for key engineering deliverables and formally transmit SME comments to the EPCM, tracking their disposition to resolution.
• Coordinate with internal SMEs to capture input without disrupting R&D and piloting operations; translate SME input into formal guidance for the EPCM.
• Participate in internal design reviews, HAZOP/PHA sessions, constructability reviews, and ensure SME input is reflected in final deliverables.
• Review EPCM equipment sizing, utility requirements, and datasheets for alignment with pilot data and design intent.
• Develop understanding of the rare earth separation process and serve as technical steward of the process design basis.
• Support design and commissioning of pilot- and commercial-scale process systems, including test plans and performance verification.

Skills

PDC knowledge

BFD knowledge

PFD knowledge

P&ID knowledge

Control philosophy

PHAs/HAZOPs experience

Capital project delivery

Team collaboration

Education

Bachelor's degree in Chemical or Metallurgical Engineering

Job description

Senior Process Engineer - Capital Projects (Round Top, TX)

Wheat Ridge, CO - Hybrid or Remote

Who we are:

We are on a mission to become a leading supplier of critical materials that enable the green energy and technology revolution. Our materials and technologies are required for the electric vehicle, green energy, consumer electronics, and defense industries, and our battery grade lithium and tech metals are needed for chipsets, semiconductors, and 5G.

We have a substantial interest in the Round Top, Heavy Rare Earth, Lithium and Critical Minerals deposit in West Texas. We have also developed the United States’ first rare earth and critical minerals processing facility and we own the only scalable, sintered neo-magnet manufacturing system in the Western Hemisphere. By developing this fully integrated, US-based “mine-to-magnet” critical mineral supply chain, we are poised to become the leading domestic supplier to these industries.

What you can expect:

At USA Rare Earth, we are pioneers and problem solvers, technologists and team players. Together, we:

Build Solutions

If our task was a simple one, it would already be done. We are creative and solution-oriented, and we think outside the box to solve important problems. We know that a range of expertise and technologies is needed for success, and we work across sectors and alongside customers to deliver world‑class solutions in sustainable ways.

Deliver Quality

When we do things, we do them well. We believe that top‑tier quality leads to industry competitiveness and we hold ourselves to the highest quality standards. We move fast when executing, but safety, quality, and excellence always come first.

Lead responsibly

We have a responsibility to the planet, our consumers, our country, and each other. We put safety at the center of all we do, take accountability for our actions, incorporate sustainable practices in our processes and act with the financial best interest of our investors and consumers in mind.

Win Together

Establishing a rare earth magnet supply chain is a big undertaking – and getting there is a team effort. We communicate openly, work together and challenge each other in pursuit of our goals. With every step we take we learn and get better.

Role Summary

We are seeking a Senior Process Engineer - Capital Projects, to serve as the owner's representative interfacing with our EPCM contractor on the Round Top Rare Earth Project during our ongoing Definitive Feasibility Study (DFS) and through project execution. 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.

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

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.