Senior Process Engineer

Alcoa; New Kensington (Westmoreland County); On-site; USD 110,000 - 160,000; Full time

Benefits offered by this job

Competitive compensation

Flexible spending accounts

401(k) with employer match

Paid holidays

Paid vacation

Employee Assistance Program (EAP)

Job summary

Alcoa Corporation is seeking a Senior Process Engineer to develop, validate, scale, and industrialize the ASTRAEA electrolysis process from lab to pilot to commercial deployment at the ATC and beyond.

You will own safe, reliable operation, transfer technology between labs and plants, and mentor teams while traveling to facilities to ensure readiness and implementation success.

Qualifications

• Bachelor's Degree in a STEM discipline.
• 7+ years of process engineering experience in electrolysis, metals, manufacturing or related heavy industry.
• Experience scaling technologies from lab/pilot to startup and commercial operation.
• Strong expertise in process optimization, troubleshooting, RCA, controls, data analysis and CI.

Responsibilities

• Lead development, optimization, and scale-up of ASTRAEA electrolysis from lab testing through pilot and commercial deployment.
• Provide technical support for process performance, including troubleshooting and root cause analysis.
• Establish and maintain critical process parameters, standards, and control strategies.
• Lead technology transfer between research, pilot, and operating facilities; ensure commissioning and startup readiness.
• Collaborate with cross-functional teams to solve complex technical challenges and drive projects.
• Support process safety, risk management, and regulatory compliance.
• Mentor engineers and operations staff; provide technical leadership for pilot ops and future deployments.
• Travel ~30%, primarily to Alcoa facilities for alignment, transfer, training and readiness.

Skills

Process engineering experience

Electrolysis/metals industry knowledge

Root cause analysis

Data analysis

Education

Bachelor's Degree in STEM

Master's Degree or Professional Engineer license (preferred)

Job description

Shape Your World

At Alcoa, you will become an essential part of our purpose: to turn raw potential into real progress. The way we see it, every Alcoan is a work-shaper, team-shaper, idea-shaper & world-shaper.

The Senior Process Engineer develops, validates, scales, and industrializes the ASTRAEA electrolysis process from laboratory and pre-pilot operations at the Alcoa Technical Center (ATC) through a pilot deployment. The role provides senior-level technical ownership for safe, reliable, and efficient operation; translates ATC learning into a controlled technology package; and aligns process design, operating parameters, procedures, training, commissioning, and startup support across ATC and pilot facility.

About the Role:

• Lead the development, optimization, and scale-up of Alcoa's proprietary ASTRAEA™ electrolysis technology from laboratory testing through pilot and commercial implementation.


• Provide technical support of process performance, including troubleshooting, root cause analysis, and continuous improvement initiatives to enhance safety, quality, reliability, and productivity.


• Establish and maintain critical process parameters, 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 successful commissioning, startup, training, and long-term operational readiness.


• Collaborate with cross-functional teams, engineering partners, suppliers, and plant personnel to solve complex technical challenges and drive project execution.


• Support process safety, risk management, and regulatory compliance through hazard assessments, management of change (MOC), and implementation of corrective actions.


• Mentor engineers and operations teams while providing technical leadership for pilot operations, process innovation, and future technology deployment across global sites.


• Travel approximately 30%, primarily to Alcoa facilities, for alignment, transfer, training, commissioning, and readiness.

What you can bring to this role:

• Basic 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.

Preferred Qualifications

• Bachelor's degree in Chemical or Mechanical engineering


• Master's Degree and/or Professional Engineer license including 5+ years' experience in process engineering within electrolysis, metals, manufacturing, chemical processing, or other heavy industrial environments.

What we offer:

• Competitive compensation packages, including pay-for performance variable pay, recognition and rewards programs, and stock-based compensation awards (3-year vesting schedule)


• Flexible spending accounts and generous employer contribution to the HSA


• 401(k), employer match up to 6%, additional employer retirement income contribution (no vesting period), and a non-qualified deferred compensation plan


• 12 paid holidays per year.


• 15 days of paid vacation (pro-rated from hire date).


• Employee Assistance Program (EAP)

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About the Location

Every day is a new and exciting challenge at the Alcoa Technical Center in New Kensington, PA, just north of Pittsburgh. We develop new technologies with our Breakthrough Technologies team that has the potential to impact the life of millions of people and foster the sustainable footprint from Alcoa to the world. It was here where we developed the technology recently announced in partnership with Rio Tinto, called ELYSIS™, where we will produce aluminum with ZERO emission of greenhouse gases. In fact, we will actually be generating oxygen to our atmosphere during the aluminum production process- a revolution to the aluminum industry!

We are values led, vision driven and united by our purpose of transforming raw potential into real progress. Our commitments to Inclusion, Diversity & Equity include providing trusting workplaces that are safe, respectful and inclusive of all individuals, free from discrimination, bullying and harassment and that our workplaces reflect the diversity of the communities in which we operate.

As a proud equal opportunity workplace and affirmative action employer, Alcoa is dedicated to providing equal opportunities and equal access to all individuals regardless of a person's gender, age, race, ethnicity, sexual orientation, gender identity, religion, nation of origin, disability, veteran status, language spoken or any other characteristic or status protected by the laws or regulations in the places where we operate.

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