Senior Process Engineer - US MMM

WorleyParsons; Mesa (AZ); On-site; USD 90,000 - 120,000; Full time

Job summary

A leading engineering company is seeking a Senior Process Engineer based in Mesa, Arizona, to support metallurgical processes in mining and mineral processing. The ideal candidate will have over 10 years of experience, a bachelor's degree in a related field, and expertise in process engineering within an EPCM environment. Responsibilities include process design, optimization, and collaboration with various engineering teams to deliver safe and effective solutions while ensuring compliance with quality standards.

Qualifications

• 10+ years of experience in Mining, Minerals & Metals industry.
• Experience in EPCM/Engineering Services environment.
• Strong understanding of process plant infrastructure interfaces.

Responsibilities

• Provide engineering support for various metallurgical processes.
• Analyze performance data to identify process improvements.
• Collaborate with multidisciplinary teams for project execution.

Skills

Metallurgical process engineering

Communication

Analytical problem-solving

Leadership

Education

Bachelor's degree in Metallurgical Engineering, Mineral Processing, or Chemical Engineering

Job description

Job Title: Senior Process Engineer – US MMM (MES002B)

Company: Worley

Location: Mesa, Arizona

Employment Type: Full‑time

Reporting Manager Title: Director, Engineering

Purpose

Worley is seeking an experienced Metallurgical Senior Process Engineer to support the development and execution of mining and mineral processing facilities. The role focuses on process plant design, metallurgical performance and integration with site infrastructure, supporting projects from early studies through detailed engineering and commissioning. This position plays a key technical role in delivering safe, operable and cost‑effective process plant solutions in line with Worley’s Engineering Execution model.

Responsibilities

• Provide metallurgical and process engineering support for crushing, grinding, classification, flotation, leaching, thickening, filtration, and SX/EW circuits in line with project scope.
• Analyze metallurgical, operating and plant performance data to identify process improvement, optimization and debottlenecking opportunities.
• Review, interpret, and apply laboratory, pilot plant, and site metallurgical test work data to flowsheet development, design criteria and equipment selection.
• Develop and maintain the process design basis, including metallurgical criteria, recovery targets, throughput assumptions, operating philosophy, and design margins.
• Perform and validate metallurgical and process calculations, including mass balances, metal recoveries, energy and heat balances and comprehensive water balances.
• Develop and maintain metallurgical and process simulation models (e.g., MetSim or equivalent) to support flowsheet evaluation, equipment sizing, optimization and trade‑off studies.
• Prepare, review and support delivery of core process engineering deliverables including PFDs, P&IDs, metallurgical reports, calculation packages, equipment data sheets and specifications.
• Collaborate with process engineers and multidisciplinary teams (mechanical, piping, electrical, instrumentation, IS/automation, civil and structural) to deliver integrated and constructible designs.
• Provide metallurgical input to equipment sizing, package definition, vendor technical evaluations and review of supplier data and documentation.
• Accurately mark up process and metallurgical designs and calculation updates to support drafting and document control activities.
• Ensure engineering deliverables align with project schedules, quality requirements and EPCM execution frameworks.
• Review technical work prior to issue to verify accuracy, compliance with standards and fitness for purpose.
• Support construction, commissioning, ramp‑up and performance testing through technical reviews, troubleshooting and operational guidance.
• Provide remote and occasional site‑based commissioning and operational support to resolve metallurgical and process‑related issues.
• Assist in developing commissioning plans and performance testing criteria for metallurgical and process systems.
• Identify, assess and support mitigation of process‑related technical, operational and execution risks.
• Prepare clear and concise metallurgical reports, technical memoranda, performance summaries and study documentation.
• Develop and maintain metallurgical accounting systems and reconciliation models to support design validation and operational assessments.
• Ensure technical documentation is reviewed, approved and issued in accordance with quality management systems.
• Participate in HAZID, HAZOP and process risk assessments, providing metallurgical input to hazard identification and mitigation recommendations.
• Ensure metallurgical designs and operating philosophies comply with safety, environmental, statutory and regulatory requirements.
• Adhere to company engineering procedures, technical standards, quality plans and safety policies.
• Liaise with project managers, discipline leads and stakeholders to align metallurgical scope with project objectives, scope, schedule and budget.
• Identify and manage risks associated with process design, metallurgical performance, equipment selection and infrastructure interfaces.
• Support management of schedule, cost, quality and scope for assigned metallurgical and process engineering activities.
• Conduct all client and stakeholder interactions in a professional, constructive and respectful manner.
• Communicate technical issues, design intent and project progress clearly with internal and external stakeholders.
• Coordinate with client and third‑party discipline engineers to ensure compliance with project requirements and specifications.
• Support relationship development and Worley brand representation through technical excellence and collaborative engagement.
• Participate in site walk‑downs, project meetings, design reviews and incorporation of review comments.

Required Experience

• Bachelor’s degree in Metallurgical Engineering, Mineral Processing, Chemical Engineering or equivalent.
• 10+ years’ experience in the Mining, Minerals & Metals industry with strong exposure to metallurgical process plants.
• Proven experience delivering process engineering in an EPCM/Engineering Services environment.
• Experience across conceptual studies, PFS, FS and detailed engineering, including commissioning support.
• Strong understanding of process plant infrastructure interfaces and utilities.

Preferred Experience

• Experience in base metals and/or copper processing circuits.
• Exposure to large‑scale concentrators, hydrometallurgical or metallurgical processing facilities.
• Experience supporting NI 43‑101 / SK‑1300 study inputs (process sections).
• Site or operational experience is highly advantageous.
• Familiarity with mining safety and environmental requirements.
• Mining regulatory/MSHA certification and experience.

Additional Skills

• Excellent verbal and written communication skills, with the ability to interact effectively with diverse clients.
• Strong analytical and problem‑solving abilities to address complex technical and operational challenges.
• Demonstrated leadership in managing critical projects with a focus on safety, efficiency and value optimization.
• Ability to innovate and develop new processes or technologies to improve operational efficiency and environmental sustainability.

E‑Equal Employment Opportunity: We provide equal employment opportunities to all qualified applicants and employees without regard to age, race, creed, color, religion, sex, national origin, ancestry, disability status, veteran status, sexual orientation, gender identity or expression, genetic information, marital status, citizenship status or any other basis as protected by federal, state or local law.

Our policy is to conduct background checks for all candidates who accept an offer of employment with us.

Please note: No agency representation or submissions will be recognized for this vacancy.