Senior Process Engineer

Alcoa • US ATR New Kensington, PA

2d • Onsite

About The Position

The Senior Process Engineer develops, validates, scales, and industrializes Alcoa’s proprietary ASTRAEA electrolysis process, advancing it from laboratory and pre-pilot operations at the Alcoa Technical Center through pilot deployment and toward commercial implementation. The role provides senior-level technical ownership for safe, reliable, and efficient process operation and translates technical learning into controlled technology packages. It aligns process design, operating parameters, procedures, training, commissioning, and startup support across the Technical Center and pilot facility.

The position leads process development, optimization, and scale-up; supports process performance and continuous improvement; and establishes operating standards, critical parameters, and control strategies. It leads technology transfer among research, pilot, and operating facilities, collaborating with cross-functional teams, engineering partners, suppliers, and plant personnel. The role also supports process safety, risk management, and regulatory compliance, and provides technical leadership and mentoring for pilot operations and future technology deployment. Travel is approximately 30%, primarily to Alcoa facilities.

Requirements

• Bachelor’s degree in a STEM discipline.
• At least 7 years of process engineering experience in electrolysis, metals, manufacturing, chemical processing, or another heavy industrial environment.
• Experience developing, scaling, and implementing technologies from laboratory or pilot-stage testing through startup, commissioning, and commercial operation.
• Expertise in process optimization, troubleshooting, root cause analysis, process controls, data analysis, and continuous improvement methodologies.

Nice To Haves

• Bachelor’s degree in Chemical or Mechanical Engineering.
• Master’s degree and/or Professional Engineer license.
• For the preferred Master’s degree and/or Professional Engineer license pathway, at least 5 years of process engineering experience in electrolysis, metals, manufacturing, chemical processing, or another heavy industrial environment.

Responsibilities

• Lead development, optimization, and scale-up of ASTRAEA electrolysis technology from laboratory testing through pilot and commercial implementation.
• Provide technical support for process performance, troubleshooting, root cause analysis, and continuous improvement to improve safety, quality, reliability, and productivity.
• Establish and maintain critical process parameters, operating standards, control strategies, and technology packages for scale-up and commercialization.
• Lead technology transfer between research, pilot, and operating facilities, including commissioning, startup, training, and long-term operational readiness.
• Collaborate with cross-functional teams, engineering partners, suppliers, and plant personnel to solve technical challenges and execute projects.
• Support process safety, risk management, and regulatory compliance through hazard assessments, management of change, and corrective actions.
• Mentor engineers and operations teams and provide technical leadership for pilot operations, process innovation, and future technology deployment across global sites.
• Travel approximately 30%, primarily to Alcoa facilities, for alignment, transfer, training, commissioning, and readiness.

Benefits

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

What This Job Offers

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