Senior Process Engineer, Mechanical Engineering

NextGenEnergyJobs; Duluth (MN); Hybrid; USD 120,000 - 180,000; Full time

Job summary

NextGenEnergyJobs seeks a Senior Process Engineer to lead planning, design, and execution of complex industrial process systems for mining, minerals processing, and heavy industrial facilities.

You will develop PFDs, P&IDs, mass and energy balances, and equipment specifications, while coordinating with mechanical, electrical, and environmental teams. Travel to active facilities is expected, and mentoring junior engineers will be part of the role.

Qualifications

• Lead engineer on multidisciplinary industrial projects.
• Strong knowledge of process design, hydraulic systems, and piping design.
• Experience with PFDs and P&IDs, calculations, and specifications.
• Excellent communication, leadership, and coordination skills.

Responsibilities

• Develop and review process flow diagrams, piping and instrumentation diagrams, mass and energy balances.
• Design and specify industrial process systems including piping, pumping, and bulk solids handling.
• Perform hydraulic calculations, equipment sizing and process analyses.
• Develop equipment specs and procurement packages.
• Coordinate with multiple engineering disciplines.
• Mentor junior engineers and establish design standards.

Skills

Lead engineer on multidisciplinary P&/

Process design methodologies

Hydraulic systems design

Industrial pumping systems

Bulk materials handling

Process safety principles

Client engagement

Team mentoring

Quality reviews

Education

Bachelor's degree in chemical/mechanical/mining/metallurgical engineering or related

Professional Engineer (PE)

Tools

PFDs & P&IDs proficiency

Process simulations software

Job description

We are seeking a highly skilled and motivated Senior Process Engineer to lead the planning, design, and execution of complex industrial process systems for mining, minerals processing, material handling, and heavy industrial facilities.

Responsibilities

• Develop process flow diagrams (PFDs), piping and instrumentation diagrams (P&IDs), mass and energy balances, and process design criteria.
• Design and specify industrial process systems including: process piping systems, slurry transport systems, pumping and dewatering systems, bulk solids handling systems, conveying systems, ore handling and crushing facilities, material storage and transfer systems, dust collection and ventilation systems, water treatment and process water systems, or utility systems supporting industrial operations.
• Perform hydraulic calculations, equipment sizing, process analyses, and system evaluations.
• Develop equipment specifications and technical procurement packages for pumps, conveyors, tanks, crushers, screens, piping systems, and related process equipment.
• Evaluate facility bottlenecks and recommend process improvements that enhance safety, reliability, throughput, and operational efficiency.
• Develop project scope, budgets, schedules, and engineering work plans.
• Coordinate activities with mechanical, structural, electrical, instrumentation, civil, and environmental disciplines.
• Provide technical oversight and quality review of engineering deliverables.
• Support project managers in managing technical scope and client expectations.
• Participate in design reviews, hazard assessments, constructability reviews, and operational readiness activities.
• Work directly with clients to understand operational challenges and identify engineering solutions.
• Participate in client meetings, site visits, and facility assessments.
• Support proposal development, scope definition, and fee estimates.
• Assist in the development of long‑term client relationships and identification of future opportunities.
• Represent the firm at client presentations, industry conferences, and professional organizations.
• Mentor junior and mid‑level engineers.
• Establish engineering standards, design practices, and quality procedures.
• Contribute to process engineering best practices across the organization.
• Promote innovation, continuous improvement, and knowledge sharing within the engineering team.

Requirements

• Bachelor's degree in chemical engineering, mechanical engineering, metallurgical engineering, mining engineering, or related engineering discipline.
• Experience serving as a lead engineer on multidisciplinary industrial projects.
• Strong understanding of: process design methodologies, hydraulic systems, process piping design, industrial pumping systems, bulk solids handling, industrial equipment selection, and process safety principles.
• Experience with PFDs, P&IDs, process calculations, and engineering specifications.
• Excellent communication, leadership, and project coordination skills.
• Ability to travel periodically to active industrial facilities and project sites.
• Professional Engineer (PE) with twelve or more years of progressive engineering experience in mining, mineral processing, bulk materials handling, industrial manufacturing, or similar heavy industrial environments.
• Experience designing facilities for: mining and mineral processing, aggregate operations, metals processing, cement manufacturing, industrial manufacturing, or material handling and transportation systems.
• Experience with slurry pipelines and abrasive process systems.
• Knowledge of process simulation and modeling software.
• Familiarity with industrial control systems and instrumentation.
• Experience supporting commissioning and startup activities.
• Previous consulting engineering experience.
• Leadership experience managing engineering teams or large project scopes.