Senior Process Engineer, Capital Projects Lead

USA Rare Earth, LLC; Wheat Ridge (CO); On-site; USD 140,000 - 210,000; Full time

Job summary

USA Rare Earth, LLC seeks a Senior Process Engineer, Capital Projects to act as owner’s representative interfacing with an EPCM contractor on the Consolidated Separations Plant project from FEL-3 through project execution. The role ensures SME guidance is captured and transmitted into EPCM deliverables for high-purity rare earth oxides production.

The successful candidate will coordinate with internal process development SMEs, participate in design reviews and PHAs, and ensure compliance with

Qualifications

• Bachelor’s degree in Chemical Engineering, Metallurgical Engineering, or related field; advanced degree a plus.
• 10–15 years of process engineering experience with capital project delivery in minerals processing, hydrometallurgy, or chemical processing industries.
• Experience as owner’s representative or engineering lead interfacing with EPCM on a major capital project.
• Strong knowledge of PDC, BFD, PFD, P&ID, and control philosophy; experience managing comment review cycles.
• Ability to translate SME input into clear engineering guidance for EPCM.
• Experience participating in or leading PHAs, HAZOPs, and design reviews.
• Collaborative team player able to engage with SMEs and project management stakeholders.
• Experience with FEL-2 or FEL-3 engineering execution on a minerals/chemical plant project.
• Understanding of rare earth processing chemistry or secondary feedstock processing is a plus.

Responsibilities

• Serve as the primary liaison between USA Rare Earth’s process development team and the EPCM contractor, ensuring alignment on deliverables, schedule, and design intent.
• Lead structured review cycles for Process Design Criteria, Block Flow Diagrams, Process Flow Diagrams, Piping & Instrumentation Diagrams, and control philosophy documents.
• Coordinate with internal SMEs to capture technical input without disrupting R&D and pilot operations; translate SME input into formal guidance for EPCM.
• Participate in and lead internal design reviews, HAZOP/PHA sessions, and constructability reviews; ensure SME input is reflected in final deliverables; support PHAs and regulatory compliance.
• Review EPCM-d produced equipment sizing, utility requirements, and datasheets against pilot data and design intent.
• Develop understanding of rare earth separation process from swarf to separated oxide; act as technical steward of design basis.
• Support design and commissioning of pilot- and commercial-scale process systems, including test plans and verification.

Skills

Leadership

Owner's representative

Cross-functional collaboration

PHAs/HAZOPs experience

Process integration

Stakeholder management

Education

Bachelor's degree in Chemical or Metallurgical Engineering

Advanced degree a plus

Tools

PFD

P&ID

PDC

BFD

Job description

USA Rare Earth, LLC seeks a Senior Process Engineer, Capital Projects to act as owner’s representative interfacing with an EPCM contractor on the Consolidated Separations Plant project from FEL-3 through project execution. The role ensures SME guidance is captured and transmitted into EPCM deliverables for high-purity rare earth oxides production.

The successful candidate will coordinate with internal process development SMEs, participate in design reviews and PHAs, and ensure compliance with