Senior Process Engineer

DISA Tech; Westminster (CO); On-site; USD 110,000 - 170,000; Full time

Job summary

DISA Tech seeks a Senior Process Engineer to lead a team in developing and optimizing HPSA technology for minerals processing, tailings remediation, and resource recovery. You will conduct heavy lab work, generate high-quality data, and inform process design for commercialization across multiple markets.

You will collaborate with internal teams, consultants, and partners to support R&D, pilot campaigns, and field deployments in a dynamic startup environment.

Qualifications

• Strong mineral processing and process engineering knowledge.
• Hands-on lab testing, instrumentation, sample analysis.
• Experience with DOE, SPC, data analysis and experimental design.
• Familiarity with lab-to-production scale-up and process troubleshooting.
• Safety protocols: OSHA/MSHA/EPA and lab best practices.

Responsibilities

• Lead and mentor a team of process engineers and junior staff.
• Collaborate with lab managers on testing schedules, equipment maintenance and safety.
• Design and execute lab and pilot-scale experiments to generate robust data.
• Prepare process engineering deliverables: PFDs, mass balance, P&IDs, control philosophy.
• Support transition of lab findings into scalable field and commercial applications.
• Assist with commissioning, troubleshooting, and optimization of process control systems.
• Communicate results through technical reports and presentations.
• Drive continuous improvement in safety, quality, and environmental performance.

Skills

Mineral processing

Laboratory testing

DOE

SPC

Data analysis

Lab-to-field transfer

Communication

Safety protocols

Tools

MATLAB

Minitab

AutoCAD

Metsim

JKSimMet

Job description

Job Summary

The Senior Process Engineer will play a key role in developing, testing, and optimizing DISA's innovative HPSA technology for minerals processing, tailings remediation, and resource recovery. This role involves heavy lab work supporting the future design and execution of process experiments, generating high-quality data, and providing engineering insights to advance commercialization across multiple market applications. The Senior Process Engineer will collaborate closely with internal teams, consultants, and strategic partners to support R&D, pilot campaigns, and field deployments. The successful candidate will thrive in a dynamic start-up environment, wearing multiple hats and contributing to many areas of business development.

Typical Job Duties and Responsibilities

• Manage a team of process engineers, along with providing mentorship to junior staff.
• Collaborate with laboratory managers on testing schedules, equipment maintenance, and safety procedures.
• Lead the design and execution of laboratory and pilot-scale process experiments to generate robust technical data and presentation of results.
• Preparation of process engineering deliverables for capital equipment orders, including PFDs, mass balance, process design criteria, P&IDs, control philosophy, Lead internal process engineering Research and Development initiatives
• Develop and optimize process parameters using data-driven experimental design (DOE) and statistical analysis.
• Collaborate with cross-functional teams to transition laboratory findings into scalable field and commercial applications.
• Provide input to commissioning, troubleshooting, and optimization of PLC-based systems and other process control hardware/software.
• Design and execute laboratory and pilot-scale test campaigns, generating robust data sets and comprehensive technical reports.
• Structure experimental designs across a variety of mineral and waste materials to validate process performance and scalability.
• Participate in customer engagements, site visits, and technical presentations to communicate process capabilities and results.
• Support continuous improvement initiatives, including safety, quality, and environmental performance in all process-related activities.
• Stay current with emerging trends and technologies in minerals processing, remediation, and resource recovery to drive innovation.
• Abide by all policies and procedures established by DISA.
• Attend and participate in all required safety trainings.
• Assist with any task required by the direct supervisor.

Required Skills

• Strong understanding of mineral processing, and process engineering principles.
• Hands-on experience with laboratory testing methods, instrumentation, and sample analysis.
• Knowledge of process design, optimization, and troubleshooting in a lab-to-production environment.
• Familiarity with statistical process control (SPC), data analysis, and experimental design (DOE).
• Experience developing and validating process parameters using lab-scale testing.
• Understanding of safety protocols (MSHA, OSHA, EPA, or equivalent) and lab best practices.
• Familiarity with engineering software (e.g., Metsim, JKSimMet, MATLAB, Minitab, AutoCAD, or similar).
• Knowledge of scale-up from laboratory/pilot testing to full production processes.
• Experience with PFD, mass balance, P&ID, process design criteria, and control philosophy development.
• Apply strong analytical and problem-solving skills to manage multiple projects effectively.
• Communicate clearly and professionally, both verbally and in writing, to collaborate with colleagues, stakeholders, and clients.
• Organize and prioritize tasks to meet deadlines while managing multiple projects.
• Collaborate effectively as part of a team, supporting shared goals and fostering positive relationships.
• Adapt to dynamic environments and identify solutions to challenges with flexibility and problem-solving skills.
• Maintain professionalism with high attention to detail, reliability, accountability, and accuracy in all work deliverables.
• Uphold and demonstrate DISA's Values of Dedication, Innovation, Sustainability, and Accelerate Change.
• Ability to follow safety protocols and maintain compliance with OSHA/MSHA and company safety standards.
• Be a valid U.S. citizen or legally authorized to work in the United States.
• Possess a valid driver's license with a clean driving record.

Physical Requirements

• Must be able to sit and/ or stand for extended periods of time.
• Must be able to lift up to 50 lbs. occasionally.
• Must be able to interact with people and technology while either standing or sitting.
• To best service our customers, all employees must be able to communicate face-to-face and on the phone with or without reasonable accommodation.
• Ability to travel up to 25%.
• Must be able to perform repetitive tasks such as typing.

DISA Technologies provides equal employment opportunities (EEO) to all employees and applicants for employment without regard to race, color, religion, sex, national origin, age, disability, or genetics.