Senior Process Engineer, Capital Projects – EPCM Lead

USA Rare Earth, Inc.; Wheat Ridge (CO); On-site; USD 135,000 - 145,000; Full time

Job summary

USA Rare Earth in Wheat Ridge, CO, seeks a Senior Process Engineer, Capital Projects, to serve as the owner's representative interfacing with the EPCM contractor on the Consolidated Separations Plant project from FEL-3 through project execution. The role ensures SME knowledge is accurately captured, transmitted, and tracked in engineering deliverables.

Key duties include leading design reviews (PDC/BFD/PFD/P&ID), coordinating with internal SME teams, and ensuring safety, environmental, and

Qualifications

• 10–15 years of process engineering with capital projects in minerals/chem processing.
• Experience as owner's representative interfacing with EPCMs.
• Ability to translate SME input into actionable engineering guidance.
• Experience with FEL-2 or FEL-3 engineering execution in minerals/chemical plant.

Responsibilities

• Serve as the primary liaison between process development and EPCM contractor, ensuring alignment on deliverables, schedule, and design intent.
• Lead design reviews and collect SME input into final engineering deliverables.
• Coordinate with internal SMEs to capture technical input without disrupting R&D.
• Contribute to PHAs/HAZOPs and ensure regulatory compliance and safety.
• Review equipment sizing, utilities, and datasheets to align with pilot data and design intent.
• Support pilot-scale and commercial-scale system design and commissioning.

Skills

Owner's representative

EPCM coordination

PFD/P&ID review

PHAs/HAZOPs

Project leadership

Education

Bachelor's degree in Chemical Engineering

Advanced degree a plus

Tools

PDC, BFD, PFD, P&ID knowledge

Control philosophy documents

Job description

USA Rare Earth in Wheat Ridge, CO, seeks a Senior Process Engineer, Capital Projects, to serve as the owner's representative interfacing with the EPCM contractor on the Consolidated Separations Plant project from FEL-3 through project execution. The role ensures SME knowledge is accurately captured, transmitted, and tracked in engineering deliverables.

Key duties include leading design reviews (PDC/BFD/PFD/P&ID), coordinating with internal SME teams, and ensuring safety, environmental, and