Senior Process Engineer - Capital Projects (Rare Earths)

USA Rare Earth, Inc. (Nasdaq: USAR); Denver (CO); On-site; USD 135,000 - 145,000; Full time

Job summary

USA Rare Earth, Inc. seeks a Senior Process Engineer, Capital Projects to act as the owner’s representative with our EPCM contractor for the Consolidated Separations Plant project through FEL-3.

The role ensures SME input is captured and reflected in EPCM documents, with focus on process design basis across the project. The candidate will work with process development, chemistry, and piloting teams to translate SME knowledge into engineering guidance, supporting design reviews, PHAs, and

Qualifications

• Bachelor's degree in Chemical Engineering, Metallurgical Engineering, or related field.
• Advanced degree in a related area is a plus.
• 10–15 years of process engineering experience in minerals processing, hydrometallurgy, or chemical processing.
• Experience as owner’s representative or engineering lead interfacing with EPCM/EPC contractors on major capital projects.
• Strong knowledge of PDC, BFD, PFD, P&ID, and control philosophy; experience with formal comment reviews.

Responsibilities

• Serve as the primary liaison between USA Rare Earth's process development team and the EPCM contractor.
• Lead structured review cycles for Process Design Criteria, BFD, PFD, P&ID and control philosophy documents.
• Coordinate with internal SMEs to capture input and translate SME knowledge for the EPCM.
• Participate in and lead PHAs, HAZOPs, and design reviews on behalf of the owner.
• Review EPCM equipment sizing, utility requirements, and datasheets for alignment with pilot data and design intent.
• Develop understanding of the rare earth separation process from swarf feedstock to oxide production.
• Support design and commissioning of pilot- and commercial-scale process systems.

Skills

EPCM liaison

PFD/P&ID knowledge

PHAs/HAZOPs

Team collaboration

Capital project delivery

Education

Bachelor's degree in Chemical/Metallurgical Engineering or related field

Advanced degree a plus

Job description

USA Rare Earth, Inc. seeks a Senior Process Engineer, Capital Projects to act as the owner’s representative with our EPCM contractor for the Consolidated Separations Plant project through FEL-3.

The role ensures SME input is captured and reflected in EPCM documents, with focus on process design basis across the project. The candidate will work with process development, chemistry, and piloting teams to translate SME knowledge into engineering guidance, supporting design reviews, PHAs, and