Process Safety Engineer - Lithium

Job Description

Tesla’s Gulf Coast Lithium Refinery is seeking an experienced Process Safety Engineer / Process Designer to lead process safety management (PSM) and small capital project process design functions for our novel flowsheet. This role will own the site’s PSM program while driving first-principles process design, hazard identification, and risk mitigation for the conversion of spodumene concentrate to battery-grade lithium hydroxide monohydrate. You will ensure inherent safety, regulatory compliance, and operational excellence in an innovative and fast-paced environment. 

Job Responsibilities

• Lead the full implementation and continuous improvement of the site Process Safety Management (PSM) program in accordance with OSHA 29 CFR 1910.119 and EPA RMP requirements, including ownership of the 14 PSM elements (Process Safety Information, Process Hazard Analysis, Mechanical Integrity, Management of Change, etc.)
• Facilitate and document Process Hazard Analyses (PHA) using HAZOP, LOPA, What-If, and other first-principles methodologies for new and existing unit operations
• Support the Management of Change (MOC) and Pre-Startup Safety Review (PSSR) processes; perform technical reviews of P&IDs, equipment datasheets, and control narratives to verify layers of protection analysis (LOPA) and inherent safety principles (e.g., minimization, substitution, moderation, simplification)
• Develop and maintain critical Process Safety Information (PSI) expectations and workflows, including stewardship of PFDs, P&IDs, mass/energy balances, relief system design basis, and consequence modeling tailored to alkaline pressure leaching conditions (elevated temperature/pressure, caustic chemistry, and lithium hydroxide handling)
• Lead or support root-cause incident investigations, near-miss reviews, and safety instrumented system (SIS) design/verification per IEC 61511; drive closure of PHA recommendations and track leading/lagging process safety metrics
• Collaborate with Production, Maintenance, Reliability, and Process Controls teams to integrate process design improvements that enhance safety, throughput, yield, and availability
• Provide technical leadership in capital project design reviews, vendor package evaluations, and commissioning support; ensure all process designs adhere to first-principles engineering (thermodynamics, reaction kinetics, fluid mechanics) and manage risks at appropriate levels
• Lead process safety audits, trainings, and contractor safety programs, serving as the site’s primary technical authority on PSM and process design

Job Requirements

• Bachelor’s Degree or eqivalent experience in Chemical Engineering and 8+ years of progressive experience in process safety engineering and/or process design within chemical, hydrometallurgical, or minerals processing facilities
• Demonstrated leadership in owning a PSM program or equivalent at the site level; proven track record facilitating HAZOP/LOPA studies and implementing risk-reduction measures
• Deep technical expertise in pressure vessel design, relief system sizing, reactive chemistry, and process simulation (Aspen, HYSYS, or equivalent); first-principles understanding of alkaline pressure leaching (beta-spodumene conversion, sodium-based leach, crystallization to LiOH·H₂O) is a significant plus
• Working knowledge of relevant codes/standards/regulations: OSHA, ASME, API, NFPA, IEC 61511, etc.
• Strong leadership and communication skills; ability to influence cross-functional teams and drive culture of process safety excellence in a fast-paced, startup-to-steady-state refinery environment
• Experience with DCS/PLC integration for safety systems, root-cause analysis tools (e.g., 5-Why, Apollo), and digital PSM platforms is highly desirable