Senior Process Engineer – Capital Projects (Remote)

USA Rare Earth, Inc. (Nasdaq: USAR); Colorado; Hybrid; USD 120,000 - 180,000; Full time

Job summary

USA Rare Earth, Inc. is seeking a Senior Process Engineer - Capital Projects to serve as the owner's representative with the EPCM contractor on the Round Top Rare Earth Project.

You will ensure SME knowledge is captured and transmitted through engineering deliverables during DFS and project execution. The role requires 10–15 years in process engineering with capital project delivery, strong PDC/BFD/PFD/P&ID expertise, and prior EPCM interfacing experience.

Qualifications

• Bachelor's degree in Chemical Engineering, Metallurgical Engineering, or related field is required.
• 10–15 years of process engineering with capital project delivery experience.
• Experience as owner's representative or engineering lead interfacing with EPCM on major capital projects.
• Strong knowledge of PDC, BFD, PFD, P&ID and control philosophy; experience in comment review cycles.
• Ability to translate SME input into actionable guidance for EPCM teams.
• Experience with PHAs, HAZOPs and design reviews.
• FEL‑2 or FEL‑3 execution experience on minerals processing or chemical plants is preferred.
• Knowledge of rare earth processing chemistry or secondary feedstock processing is a plus.

Responsibilities

• Serve as liaison between USA Rare Earth's process development team and the EPCM contractor to ensure alignment on technical deliverables, schedule, and design intent.
• Lead structured reviews for key engineering deliverables and formally transmit SME comments to the EPCM, tracking their disposition to resolution.
• Coordinate with internal SMEs to capture input without disrupting R&D and piloting operations; translate SME input into formal guidance for the EPCM.
• Participate in internal design reviews, HAZOP/PHA sessions, constructability reviews, and ensure SME input is reflected in final deliverables.
• Review EPCM equipment sizing, utility requirements, and datasheets for alignment with pilot data and design intent.
• Develop understanding of the rare earth separation process and serve as technical steward of the process design basis.
• Support design and commissioning of pilot- and commercial-scale process systems, including test plans and performance verification.

Skills

PDC knowledge

BFD knowledge

PFD knowledge

P&ID knowledge

Control philosophy

PHAs/HAZOPs experience

Capital project delivery

Team collaboration

Education

Bachelor's degree in Chemical or Metallurgical Engineering

Job description

USA Rare Earth, Inc. is seeking a Senior Process Engineer - Capital Projects to serve as the owner's representative with the EPCM contractor on the Round Top Rare Earth Project.

You will ensure SME knowledge is captured and transmitted through engineering deliverables during DFS and project execution. The role requires 10–15 years in process engineering with capital project delivery, strong PDC/BFD/PFD/P&ID expertise, and prior EPCM interfacing experience.