Senior Process Engineer

Alcoa • New Kensington, PA

30d • Onsite

About The Position

Shape Your World At Alcoa, you will become an essential part of our purpose: to turn raw potential into real progress. The way we see it, every Alcoan is a work-shaper, team-shaper, idea-shaper & world-shaper. The Senior Process Engineer role is to develop, validate, and industrialize a developing electrolysis processing pathway that is essential for processes technical feasibility, commercial viability, and safe long‑term operation. Furthermore, to ensure the electrolysis process operates safely, reliably, and efficiently by providing senior‑level technical ownership, solving complex process problems, and leading improvements that optimize safety, quality, throughput, and cost. About the Role: Serve as the technical owner for assigned electrolysis and/or R&D processes Monitor process performance, identify deviations, and lead root cause investigations Develop and implement process improvements to enhance safety, stability, productivity, quality, and cost performance Establish and maintain process control limits, operating standards, and best practices Lead complex troubleshooting efforts involving process upsets, quality excursions, or equipment interactions Apply statistical, metallurgical, and process engineering principles to diagnose issues Support production teams with real time technical decision making during abnormal conditions Act as a subject matter expert for assigned processes Lead continuous improvement initiatives using Lean, Six Sigma, or similar methodologies Support capital and expense projects by defining process requirements, reviewing designs, and supporting commissioning/start up Develop technical specifications, operating procedures, and control strategies for new or modified equipment Evaluate new technologies, raw materials, or process changes for operational fit Help lead process transfer from R&D to pilot to plant scenarios during technology advancement. Ensure all processes operate in compliance with EHS policies, regulatory requirements, and internal standards Lead or support hazard analyses, risk assessments, and Management of Change (MOC) activities Provide technical input for incident investigations and corrective actions Promote a strong safety culture through visible leadership and technical rigor Work closely with Operations, Maintenance, Reliability, Quality, and Automation teams Mentor and coach junior process engineers and technicians Provide technical training and knowledge transfer to operations personnel Communicate process performance, risks, and improvement plans to leadership Ability to work in industrial environments, including exposure to heat, noise, and production equipment Ability to occasionally travel to plant sites or vendors Participation in off hour or on call technical support as needed

Requirements

• Bachelor’s degree in chemical engineering, Metallurgical Engineering, Materials Science, Mechanical Engineering, or a closely related engineering discipline
• 7–10+ years of progressive experience in manufacturing or smelting process engineering
• Demonstrated experience supporting continuous, high temperature, or heavy industrial operations
• Proven ability to independently lead troubleshooting process and improvement initiatives
• Experience working directly with operating crews in a plant environment
• Strong understanding of process control, mass and energy balances, and industrial data analysis
• Experience with process monitoring tools, statistical analysis, and manufacturing KPIs
• Familiarity with MOC, hazard analysis, and root cause problem solving methodologies
• Proficiency with standard engineering and data tools (e.g., Excel, process historians, SPC software)
• Demonstrated technical leadership without direct authority
• Strong communication skills with the ability to translate complex technical concepts into practical guidance
• Ability to prioritize work in a fast paced, operational environment
• Comfortable making data driven decisions under production constraints

Nice To Haves

• Advanced degree (Master’s) or Professional Engineer (PE) license preferred but not required.
• Demonstrated technology scale up and/or plant start up is preferred but not required.

Responsibilities

• Serve as the technical owner for assigned electrolysis and/or R&D processes
• Monitor process performance, identify deviations, and lead root cause investigations
• Develop and implement process improvements to enhance safety, stability, productivity, quality, and cost performance
• Establish and maintain process control limits, operating standards, and best practices
• Lead complex troubleshooting efforts involving process upsets, quality excursions, or equipment interactions
• Apply statistical, metallurgical, and process engineering principles to diagnose issues
• Support production teams with real time technical decision making during abnormal conditions
• Act as a subject matter expert for assigned processes
• Lead continuous improvement initiatives using Lean, Six Sigma, or similar methodologies
• Support capital and expense projects by defining process requirements, reviewing designs, and supporting commissioning/start up
• Develop technical specifications, operating procedures, and control strategies for new or modified equipment
• Evaluate new technologies, raw materials, or process changes for operational fit
• Help lead process transfer from R&D to pilot to plant scenarios during technology advancement.
• Ensure all processes operate in compliance with EHS policies, regulatory requirements, and internal standards
• Lead or support hazard analyses, risk assessments, and Management of Change (MOC) activities
• Provide technical input for incident investigations and corrective actions
• Promote a strong safety culture through visible leadership and technical rigor
• Work closely with Operations, Maintenance, Reliability, Quality, and Automation teams
• Mentor and coach junior process engineers and technicians
• Provide technical training and knowledge transfer to operations personnel
• Communicate process performance, risks, and improvement plans to leadership
• Ability to work in industrial environments, including exposure to heat, noise, and production equipment
• Ability to occasionally travel to plant sites or vendors
• Participation in off hour or on call technical support as needed

Benefits

• Competitive compensation packages, including pay-for performance variable pay, recognition and rewards programs, and stock-based compensation awards (3-year vesting schedule)
• Flexible spending accounts and generous employer contribution to the HSA
• 401(k), employer match up to 6%, additional employer retirement income contribution (no vesting period), and a non-qualified deferred compensation plan
• 12 paid holidays per year.
• 15 days of paid vacation (pro-rated from hire date).
• Employee Assistance Program (EAP)

What This Job Offers

• Job Type: Full-time
• Career Level: Mid Level