Senior Process Engineer - Mechanical Engineering

Salary Range: 110500 to 155000 (Currency: USD) (Pay period: per-year-salary)

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. This role is responsible for developing process solutions that improve operational performance, safety, reliability, and efficiency while collaborating closely with multidisciplinary engineering teams and clients.

The ideal candidate possesses extensive experience designing and evaluating industrial process facilities, including process piping systems, slurry transport systems, bulk material handling equipment, pumping systems, and plant utility infrastructure. The Senior Process Engineer serves as a technical leader and trusted advisor throughout project planning, design, construction, and commissioning activities.

Under our “Seller-Doer” approach to business development, you will collaborate with the Vice President of Mining, Market Managers, and other Group Managers to develop and implement a marketing plan, track prospective business opportunities, make strategic decisions for project pursuits, lead proposal development efforts, and represent TKDA at project interviews. You will also be expected to cultivate and maintain relations with key decision makers and representatives of current and prospective clients by attending local and regional conferences and networking events.

Location and Work Arrangement

Our preference is for this position to be based out of Duluth, MN or Bloomington, MN; however, we will consider candidates residing within greater Minnesota and Wisconsin if experience and qualifications align with this position and market development initiatives. TKDA offers flexible hybrid work arrangements, with employees typically working three days in the office and two days remotely, in alignment with business needs. Regular travel to TKDA offices, project locations, industry-specific conferences will be required along with team events for remote candidates to foster collaboration, strengthen relationships, and support project success.

What You'll Do

Process Engineering & Design

Lead process engineering efforts for mining, mineral processing, aggregate, metals, and heavy industrial projects.

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.

Project Leadership

Serve as Lead Process Engineer on multidisciplinary industrial projects.

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.

Client Management & Business Development

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.

Technical Leadership

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.

Required Qualifications

• 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.

Advantageous Qualifications

• 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.

• Health Benefits: Enjoy medical, dental, vision, and life insurance from day one
• Annual Incentive Plan: Eligible for discretionary bonuses
• HSA Contributions: Receive monthly employer contributions if you choose an HSA-eligible plan
• 401(k) Match: Get employer matching on your 401(k) deferrals
• ESOP: Benefit from our Employee Stock Ownership Plan, funded entirely by company profits
• Paid Time Off: Accrue PTO based on your professional experience and enjoy eight paid holidays per year