CAPEX Process Engineer

ArcelorMittal•Saraland, AL

53d•Hybrid

About The Position

ArcelorMittal Calvert is seeking a CAPEX Process Engineer to provide technical leadership and support for process technology, metallurgical systems, and production equipment activities. This role is crucial for supporting the company's business objectives and ensuring the successful integration, commissioning, and performance of EAF/Caster technologies to achieve safe, reliable, and efficient production. The position involves working on large-scale steel industry capital projects from concept through commissioning, startup, and performance guarantee. The ideal candidate will have a strong understanding of EAF and continuous casting processes, experience with process equipment in a heavy industrial environment, and the ability to collaborate with various stakeholders including OEMs, engineering firms, contractors, operations, and maintenance organizations. This role requires strong analytical, technical, and problem-solving skills, as well as excellent communication abilities to interpret technical documents and coordinate complex project activities.

Requirements

Bachelor’s degree in metallurgical engineering, Materials Engineering, Chemical Engineering, Mechanical Engineering, Process Engineering, or a related technical discipline
At least 10 years of experience in steelmaking, continuous casting, process engineering, metallurgical technology
Experience working on large-scale steel industry capital projects from concept through commissioning, startup, and performance guarantee
Strong understanding of EAF and continuous casting processes and technology
Experience with process equipment, metallurgical systems, and production equipment in a heavy industrial environment
Experience working with OEMs, engineering firms, contractors, operations, and maintenance organizations
Strong understanding of process flow, operating parameters, equipment functionality, product requirements, and process performance requirements
Experience evaluating equipment capability against existing plant conditions and required product mix
Strong analytical, technical, and problem-solving skills
Strong interpersonal communication skills, both written and verbal
Ability to read and interpret process flow diagrams, P&IDs, equipment layouts, process descriptions, technical specifications, and engineering drawings
Experience coordinating engineering, construction, maintenance, operations, technology suppliers, and project teams

Nice To Haves

Extensive experience with EAF and continuous casting technology
Experience with EAF process optimization, furnace operation, power input, oxygen/carbon injection, slag practices, electrode systems, and productivity improvement
Experience with continuous casting technology, including mold, secondary cooling, oscillation, withdrawal, straightening, cutting, and strand handling systems
Experience with metallurgical process control, steel temperature, chemistry, quality, and process consistency
Knowledge of EAF process technology, slag management, refining practices, alloying, injection systems, and energy optimization
Knowledge of caster process technology, mold metallurgy, solidification, secondary cooling, breakout prevention, and casting quality
Experience with equipment such as EAFs, ladle furnaces, ladle handling systems, tundish systems, casting machines, mold systems, oscillators, withdrawal units, straighteners, torch cutting systems, and strand handling equipment
Experience with FES and associated material handling, process, and auxiliary systems
Experience with process gas, oxygen, natural gas, carbon injection, alloying, cooling water, hydraulic, lubrication, and other process support systems
Knowledge of process modeling, mass and energy balances, production modeling, and process simulation
Experience with metallurgical and process data collection, analysis, trending, and optimization
Experience developing equipment specifications, process design criteria, equipment performance requirements, and technical bid packages
Experience evaluating OEM technical proposals and conducting technical bid evaluations
Experience leading Factory Acceptance Testing (FAT), Site Acceptance Testing (SAT), commissioning, startup, and performance guarantee testing
Experience developing and executing performance guarantee test protocols and validating OEM contractual performance commitments
Experience with equipment reliability, maintainability, and lifecycle optimization
SAP experience preferred
Experience with continuous improvement methodologies and structured problem-solving tools
Knowledge of applicable industry standards, company engineering standards, and metallurgical/process safety requirements

Responsibilities

Provide process, metallurgical, and technology equipment leadership for the Complex II EAF/Caster Project, including EAF, Caster, FES, Water Systems, and associated auxiliaries.
Lead process and technology activities from concept/FEED through engineering, procurement, construction, commissioning, performance guarantee testing, startup, and production ramp-up.
Define process requirements, operating philosophies, design criteria, equipment specifications, performance requirements, and technical standards.
Ensure OEM equipment and technology are aligned with existing process conditions, operating practices, raw materials, utilities, required product mix, production targets, and quality requirements.
Validate OEM designs and equipment capabilities against actual plant conditions, future production requirements, product grades, and operating scenarios; identify and resolve gaps.
Serve as the technical liaison between process technology, engineering, project management, construction, operations, maintenance, OEMs, and contractors.
Lead or support technical evaluation, selection, and procurement of EAF, caster, FES, metallurgical, process, and auxiliary equipment.
Review OEM proposals, designs, calculations, process philosophies, equipment specifications, technical documentation, and performance commitments.
Coordinate process and technology requirements with mechanical, piping, electrical, automation, instrumentation, civil, structural, refractory, and other disciplines.
Participate in design reviews, HAZOPs, constructability, operability, maintainability, and process risk assessments.
Provide technical leadership for EAF and caster process technology, including furnace operation, injection systems, slag practices, material additions, mold systems, secondary cooling, withdrawal, straightening, cutting, and strand handling.
Establish and validate critical process parameters, operating windows, equipment capabilities, production targets, and process control requirements.
Coordinate integration of process technology with Level 1/Level 2 automation, instrumentation, data acquisition, and production systems.
Lead commissioning and startup of assigned process and technology equipment, coordinating OEMs, engineering, contractors, operations, and maintenance.
Develop and execute commissioning plans, readiness requirements, functional testing, process trials, startup activities, and production ramp-up.
Lead the development and execution of Performance Guarantee Test Plans, including test criteria, conditions, measurement methods, data requirements, and acceptance thresholds.
Ensure performance guarantee testing reflects agreed-upon company process conditions and product mix, and validate OEM performance against contractual and technical requirements.
Lead performance data collection and analysis and coordinate corrective actions, retesting, and resolution of performance gaps with OEMs and engineering teams.
Verify OEM equipment achieves required capacity, productivity, yield, quality, energy performance, reliability, availability, and other contractual guarantees, as applicable.
Provide technical recommendations for final equipment acceptance and support project turnover, ensuring commissioning, performance, operating, and as-built documentation is complete.
Analyze process and metallurgical data to identify constraints, equipment limitations, quality issues, and opportunities to improve yield, productivity, energy consumption, quality, casting speed, reliability, and operating cost.
Support production ramp-up, stabilization, process optimization, and continuous improvement following commissioning.
Provide technical training and knowledge transfer to operations, maintenance, process control, and engineering personnel.
Coordinate OEM and contractor activities during installation, commissioning, startup, and performance testing, ensuring safe and effective execution.
Provide technical updates to management, support project schedules and execution strategies, and participate in walkdowns, inspections, punch-list activities, and equipment acceptance.
Demonstrate the company values of Safety, Teamwork, Accountability, Relationships, and Sustainability.
Fulfill the commitment to ensure a safe and healthy work environment.
Fulfill the responsibilities required to achieve the Quality Commitment.
Demonstrate commitment to teamwork by fostering an environment that embodies trust and respect.
Ensure working knowledge of competencies as defined in ISO 14001 (current version), IATF 16949 (current version), and ISO 17025 (current version).

Benefits

High-deductible health insurance plan with a Health Savings Account (HSA)
Traditional PPO plan with a Flex Spending Account (FSA) option
Dental coverage
Vision coverage
Employee assistance program (EAP)
Life insurance
Short-term disability plans
Long-term disability plans
AD&D insurance
401k with an employer match of 6%
Competitive pay
Quarterly bonuses
Comprehensive relocation package
Paid vacation, starting at 13 days per year, increasing with tenure
10 paid holidays
Bereavement leave
Parental leave
Hybrid work opportunities
Flexible work hours
Alternative schedules
Tuition reimbursement program
In-house training on professional topics, technical skills, and leadership competencies
On-site 24/7 convenience mini markets
Community involvement opportunities