Principal Process Design Engineer - Minerals Processing

Placements24; Mbombela (Nelspruit); On-site; ZAR 1,800,000 - 2,800,000; Full time

Benefits offered by this job

Relocation assistance

Performance bonuses

Medical aid & retirement fund

International travel opportunities

Job summary

Placements24 seeks a Principal Process Design Engineer to lead conceptualization, design and optimization of mineral processing plants near Nelspruit, Mpumalanga. You will guide cross-functional teams, oversee feasibility studies, and ensure safety and environmental compliance.

The ideal candidate has 12+ years in mining/process design, strong expertise in crushing, grinding, flotation, leaching, and proficiency in METSIM, HSC Chemistry, and Aspen Plus.

Qualifications

• Master's degree in Chemical or Metallurgical Engineering or related field.
• Minimum 12 years of process design experience in mining/mineral processing.
• Experience with mineral processing unit operations (crushing, grinding, flotation, leaching).
• Proficiency in process simulation software and data analysis.
• Experience leading design teams on major capital projects and strong PSM/HAZOP knowledge.

Responsibilities

• Lead the design and development of new mineral processing plants and optimize existing facilities.
• Develop PFDs, P&IDs, and equipment specifications.
• Use METSIM/HSC Chemistry/Aspen Plus to model and optimize plant performance.
• Conduct detailed technical/economic evaluations for design options.
• Oversee selection and procurement of major equipment and ensure safety/environmental compliance.
• Collaborate with project management and other engineering disciplines throughout the project lifecycle.
• Provide technical leadership and mentor junior engineers.

Skills

Leadership

Communication

Project management

Education

Master's degree in Chemical Engineering

Master's degree in Metallurgical Engineering

Tools

METSIM

HSC Chemistry

Aspen Plus

Job description

About the Role

Our client, a globally recognized leader in mining and mineral processing, is seeking a highly experienced Principal Process Design Engineer to spearhead their process engineering activities near Nelspruit, Mpumalanga. This senior role is responsible for conceptualizing, designing, and optimizing mineral processing plants, focusing on efficiency, sustainability, and cost-effectiveness. You will lead multidisciplinary teams, manage feasibility studies, and ensure that process designs meet stringent technical, safety, and environmental standards. The ideal candidate will possess deep expertise in mineral processing unit operations (e.g., crushing, grinding, flotation, leaching), process simulation, and project execution. This is an exceptional opportunity to influence major capital projects and drive innovation in the mineral processing sector within the key industrial region of Mpumalanga.

Key Responsibilities

• Lead the design and development of new mineral processing plants and the optimization of existing facilities.
• Develop process flow diagrams (PFDs), piping and instrumentation diagrams (P&IDs), and equipment specifications.
• Utilize process simulation software (e.g., METSIM, HSC Chemistry, Aspen Plus) to model, analyze, and optimize plant performance.
• Conduct detailed technical and economic evaluations for process design options and feasibility studies.
• Oversee the selection and procurement of major processing equipment, ensuring compliance with technical requirements.
• Collaborate with project management, engineering disciplines (mechanical, electrical, civil), and construction teams throughout the project lifecycle.
• Ensure that all designs comply with relevant industry standards, safety regulations (e.g., HAZOP studies), and environmental legislation.
• Provide technical leadership and mentorship to junior process engineers and design teams.
• Stay abreast of emerging technologies and best practices in mineral processing and contribute to research and development initiatives.

Requirements

• A Master's degree in Chemical Engineering, Metallurgical Engineering, or a related field.
• A minimum of 12 years of experience in process design and engineering within the mining and minerals processing industry.
• Extensive experience with a wide range of mineral processing unit operations, including comminution, solid-liquid separation, and extractive metallurgy.
• Proficiency in process simulation software and strong data analysis capabilities.
• Demonstrated experience in leading design teams and managing process engineering aspects of major capital projects.
• In-depth understanding of process safety management (PSM) principles and HAZOP procedures.
• Excellent leadership, communication, and project management skills.
• Experience working on projects in the Nelspruit, Mpumalanga region or similar mineral processing environments is highly advantageous.

Benefits

• A highly competitive salary package, commensurate with a principal engineering role.
• Significant performance bonuses and potential for long-term incentive plans.
• Comprehensive medical aid, retirement fund, and other employee benefits.
• Relocation assistance for qualified candidates moving to the Nelspruit, Mpumalanga area.
• Opportunities for international travel and professional development.
• The chance to work on cutting-edge projects within a leading mining organization.