Senior Thermal Processing Engineer

MP Materials•Mountain Pass, CA

8d•Onsite

About The Position

The Senior Thermal Processing Engineer is responsible for supporting the operation, optimization, reliability, and design of industrial kilns, calciners, coolers, dryers, and associated rotating equipment, conveyance systems, and dust handling systems. Responsibilities include monitoring process and equipment performance, troubleshooting process and mechanical issues, and keeping equipment operating safely and efficiently. The position will lead continuous improvement and capital projects related to kiln and calciner optimization, debottlenecking, capacity improvement, equipment modifications, and design upgrades. The role requires coordination with Process Engineers, Operations, Maintenance, Reliability, Electrical, Process Controls, contractors, and equipment vendors to prioritize work and successfully execute projects.

Requirements

Bachelor’s degree in mechanical, chemical, metallurgical, or a related engineering discipline.
Experience with industrial kilns, rotary kilns, calciners, dryers, solids conveyance systems, baghouses, furnaces, or similar high-temperature equipment.
Experience with rotating equipment such as gearboxes, bearings, drives, couplings, fans, blowers, and lubrication systems.
Experience in mining, metallurgical processing, cement, chemical processing, petroleum, or another heavy industrial environment.
Strong troubleshooting, equipment optimization, and project execution experience.
Understanding of heat transfer, combustion, material flow, draft, thermal expansion, refractory systems, and mechanical reliability.
Ability to read and develop PFDs, P&IDs, equipment drawings, specifications, and technical documentation.
Ability to perform heat and mass balances, equipment sizing, throughput calculations, and technical evaluations.
Familiarity with plant control systems, PI Vision, SAP, and Microsoft Office applications.
Valid driver’s license.

Nice To Haves

10+ years’ experience in a related engineering, operations support role
Hands-on, safety-focused engineer who is comfortable working in the field.
Strong project owner who drives work from initial concept through successful operation.
Analytical and detail-oriented problem solver who uses data and field observations to make sound engineering decisions.
Proactive self-starter with a strong sense of urgency and accountability.
Effective communicator who works well with operations, maintenance, contractors, vendors, and management.

Responsibilities

Provide technical support for the operation, optimization, and reliability of kilns, calciners, coolers, dryers, and associated rotating equipment, conveyance systems, and dust handling systems.
Lead projects involving process optimization, debottlenecking, equipment modifications, capacity improvement, and design upgrades.
Analyze equipment performance, including temperature, material flow, refractory design & performance, residence time, draft, combustion, heat transfer, vibration, motor load, and product quality.
Troubleshoot buildup, plugging, refractory damage, overheating, vibration, misalignment, air leakage, and mechanical failures.
Work with Process Engineers, Operations, Maintenance, Reliability, Electrical, and Process Controls to improve equipment performance and reliability.
Develop engineering calculations, equipment specifications, scopes of work, cost estimates, schedules, and technical evaluations.
Support Capital Project teams through detailed engineering, design reviews, procurement, construction, commissioning, and startup.
Review and update PFDs, P&IDs, equipment layouts, datasheets, and engineering drawings.
Coordinate vendors, contractors, equipment procurement, installation, commissioning, and performance testing.
Manage projects from concept and design through execution, startup, and closeout.
Present equipment performance, project status, risks, and recommendations to plant and senior management.
Ensure all changes comply with safety requirements, engineering standards, and the Management of Change process.
Any other tasks as directed by management.