Senior Process Engineer - Capital Projects, Consolidated Separations

Who we are:

USA Rare Earth and the Serra Verde Group are building the world's leading rare earth enterprise—a pioneering global company that excels at every stage of the value chain, from the earth to the magnet and beyond. We operate upstream mining and processing operations in Brazil and the USA, midstream metal-making operations in the UK and France, and downstream magnet-making facilities in the USA.

Our vision is to be "The Critical Elements of Progress. Delivered Responsibly. At Global Scale." We are committed to delivering a secure, sustainable supply of rare earths and critical materials that power the modern world, with an uncompromising commitment to responsible practice. The organization operates a devolved model designed for rapid, scalable growth and the development of entrepreneurial leaders.

Our organizational model is based on the principle of clear accountability and the creation of entrepreneurial enclaves which define business units reflecting the natural components of our supply chain. Each Business Unit retains a profit motive and the responsibly to deliver shareholder returns. However, this cannot occur at the expense of overall Group value.

What you can expect:

At USA Rare Earth, we are pioneers and problem solvers, technologists and team players. Together, we:

Build Solutions: If our task was a simple one, it would already be done. We are creative and solution-oriented, and we think outside the box to solve important problems. We know that a range of expertise and technologies is needed for success, and we work across sectors and alongside customers to deliver world-class solutions in sustainable ways.

Deliver Quality: When we do things, we do them well. We believe that top-tier quality leads to industry competitiveness and we hold ourselves to the highest quality standards. We move fast when executing, but safety, quality, and excellence always come first.

Lead responsibly: We have a responsibility to the planet, our consumers, our country, and each other. We put safety at the center of all we do, take accountability for our actions, incorporate sustainable practices in our processes and act with the financial best interest of our investors and consumers in mind.

Win Together: Establishing a rare earth magnet supply chain is a big undertaking – and getting there is a team effort. We communicate openly, work together and challenge each other in pursuit of our goals. With every step we take we learn and get better.

Job Summary

We are seeking a Senior Process Engineer, Capital Projects to serve as the owner's representative interfacing with our EPCM contractor on our Consolidated Separations Plant project during FEL-3 Engineering through project execution. The Consolidated Downstream Separations Plant will produce high purity rare earth oxides from 3^rd party and internal feedstocks. The successful candidate will ensure that the knowledge and direction from our internal process development SMEs is accurately captured, formally transmitted, and tracked through the EPCM's engineering deliverables.

Key Responsibilities

• Serve as the primary liaison between USA Rare Earth's process development team and the EPCM contractor, acting as the owner's representative to ensure alignment on technical deliverables, schedule, and design intent.
• Lead structured review cycles for key engineering deliverables including Process Design Criteria (PDC), Block Flow Diagrams (BFD), Process Flow Diagrams (PFD), Piping & Instrumentation Diagrams (P&ID), and control philosophy documents. Consolidate, prioritize, and formally transmit SME comments to the EPCM. Track disposition of all comments through resolution. Liaise with external partners, including EPCMs, equipment manufacturers, engineering consultants, and regulatory agencies.
• Coordinate with USA Rare Earth's internal subject matter experts across process development, chemistry, and piloting to capture technical input efficiently without disrupting ongoing R&D and pilot operations. Translate SME knowledge into formal engineering guidance for the EPCM.
• Participate in and lead internal design reviews, HAZOP/PHA sessions, and constructability reviews on behalf of the owner. Ensure that SME input is accurately reflected in final engineering deliverables. Contribute to process hazard analyses (PHAs) and ensure compliance with environmental and safety regulations.
• Review EPCM-produced process equipment sizing, utility requirements, and equipment datasheets to ensure alignment with pilot-scale performance data and established design intent.
• Develop a thorough understanding of the rare earth separation process from swarf feedstock through MREC processing to separated rare earth oxide production. Serve as the technical steward of the process design basis in coordination with the process development SMEs.
• Support design and commissioning of pilot- and commercial-scale process systems, including test plans and performance verification.

Qualifications

• Bachelor's degree in Chemical Engineering, Metallurgical Engineering, or a related field; advanced degree a plus.
• 10–15 years of process engineering experience, with significant exposure to capital project delivery in the minerals processing, hydrometallurgy, or chemical processing industries.
• Demonstrated experience as an owner's representative or engineering lead interfacing with an EPCM or EPC contractor on a major capital project
• Strong working knowledge of engineering deliverables including PDC, BFD, PFD, P&ID, and control philosophy; experience managing formal comment review and disposition cycles.
• Ability to synthesize complex process development data and SME input into clear, actionable technical guidance for an EPCM team.
• Experience participating in or leading PHAs, HAZOPs, and design reviews.
• Collaborative team player who can engage effectively with both technical SMEs and project management stakeholders.
• Experience with FEL-2 or FEL-3 engineering execution on a minerals processing or chemical plant project.
• Understanding of rare earth processing chemistry or secondary feedstock (scrap/swarf) processing is a plus.
• Ability to travel as needed, up to 25%.

Physical Demands

The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

Specific vision abilities required by this job include close vision and distance vision. While performing the duties of this Job, the employee is regularly required to walk, stand, move, sit, carry, bend, kneel, reach, push, pull, lift, use hands and fingers, handle, or feel and talk and hear. May be required to lift and move boxes or packages not exceeding 20 pounds in weight. Some work stress inherent to the position and extended work hours may be required. 

Work Environment:
The work environment will be a mix of a typical office environment, laboratory space, and construction site.

Noise level:

Exposure will vary and include normal office noise, typical laboratory sounds (e.g., ventilation systems, equipment operation), manufacturing floor noise (e.g., machinery, forklifts), and construction site noise depending on project phase and location.

The above statements are intended to describe the general nature and level of work being performed by people assigned to this job. They are not intended to be an exhaustive list of all responsibilities, duties, skills required of personnel so classified. The reporting relationship may not reflect the most recent changes to the corporate reporting structure.

USA Rare Earth proudly supports Equal Employment Opportunities. All employment decisions are made without regard to race, color, religion, sex, national origin, age, disability, protected veteran status, or any other characteristic protected by applicable federal, state, or local law. Qualified applicants will receive consideration for employment without discrimination based on disability, protected veteran status, or any other legally protected status.

If you require assistance with the application process due to a disability, please contact [email protected] to discuss reasonable accommodations.