Senior Process Engineer

CSG is partnered with a leading global engineering, project delivery and professional services organisation supporting the energy, chemicals, resources and mining sectors.

As part of continued growth, the organisation is seeking an experienced Senior Metallurgical Process Engineer to support the development and execution of major mineral processing projects.

This is a confidential opportunity with an established business delivering projects across the full asset life cycle, from early studies and engineering through procurement, construction, commissioning and operational support.

The role is based out of their Arizona office and is primarily office based, with occasional travel required to support site activities, commissioning, ramp up and operational troubleshooting.

The Role

The successful candidate will provide senior metallurgical and process engineering expertise across mining and mineral processing projects. The role will involve flowsheet development, interpretation of metallurgical testwork, preparation of design criteria, process modelling, equipment selection and support for multidisciplinary engineering deliverables.

You will contribute across conceptual studies, pre-feasibility studies, feasibility studies, detailed engineering and project execution, helping deliver safe, operable, reliable and cost effective process plant solutions.

Key Responsibilities

• Provide metallurgical and process engineering support for crushing, grinding, classification, flotation, leaching, thickening, filtration and SX/EW circuits.
• Interpret laboratory, pilot plant and site metallurgical testwork to support flowsheet development, design criteria and equipment selection.
• Develop and maintain the process design basis, including metallurgical criteria, recovery targets, throughput assumptions, operating philosophies and design margins.
• Prepare and validate mass balances, metal recoveries, energy and heat balances, water balances and other process calculations.
• Develop and maintain metallurgical and process simulation models using MetSim or equivalent software.
• Analyse metallurgical, operating and plant performance data to identify optimisation, debottlenecking and process improvement opportunities.
• Prepare, review and support the delivery of PFDs, P&IDs, metallurgical reports, calculation packages, equipment datasheets and technical specifications.
• Provide metallurgical input into equipment sizing, package definition, vendor evaluations and supplier document reviews.
• Collaborate with mechanical, piping, electrical, instrumentation, automation, civil and structural engineering teams to deliver integrated and constructible designs.
• Ensure engineering deliverables meet project schedules, quality requirements and applicable engineering standards.
• Review technical work prior to issue, ensuring accuracy, compliance and fitness for purpose.
• Support construction, commissioning, ramp-up and performance testing through technical reviews, troubleshooting and operational guidance.
• Assist with commissioning plans and performance testing criteria for metallurgical and process systems.
• Develop and maintain metallurgical accounting systems and reconciliation models.
• Participate in HAZID, HAZOP and process risk assessments, providing metallurgical input into hazard identification and mitigation.
• Identify and manage risks associated with process design, metallurgical performance, equipment selection and infrastructure interfaces.
• Prepare clear and concise technical reports, memoranda, performance summaries and study documentation.
• Liaise with project managers, discipline leads, clients, vendors and 3rd party engineers to align technical scope with project objectives, schedule and budget.
• Participate in site walkdowns, project meetings, design reviews and the incorporation of review comments.
• Represent the organisation professionally through strong technical delivery, clear communication and collaborative stakeholder engagement.

Required Experience and Qualifications

• Bachelor's degree in Metallurgical Engineering, Mineral Processing, Chemical Engineering or a related discipline.
• At least 10 years' experience within the mining, minerals and metals industry.
• Strong experience supporting metallurgical process plants and mineral processing facilities.
• Proven experience delivering process engineering within an EPCM, engineering consultancy or engineering services environment.
• Experience across conceptual studies, PFS studies, feasibility studies, detailed engineering and commissioning support.
• Strong understanding of process plant infrastructure interfaces, utilities and multidisciplinary engineering integration.
• Experience with process calculations, metallurgical accounting and mass, water and energy balances.
• Strong verbal and written communication skills, with the ability to engage effectively with clients, project teams and technical stakeholders.
• Demonstrated ability to manage technical priorities and deliver high-quality work within project schedules and quality requirements.

Preferred Experience

• Experience with base metals and/or copper processing circuits.
• Exposure to large-scale concentrators, hydrometallurgical facilities or other complex metallurgical processing operations.
• Experience contributing to NI 43-101 or SK-1300 technical studies, particularly process and metallurgical sections.
• Previous site-based or operational experience.
• Familiarity with mining safety, environmental and regulatory requirements.
• MSHA certification or experience working within MSHA-regulated operations.
• Experience using MetSim or comparable metallurgical process simulation software.

What's on Offer

This is an opportunity to join an established global engineering organisation working on technically complex mining and mineral processing projects.

The successful candidate will have the opportunity to:

• Work across the full project life cycle, from early studies through commissioning.
• Support major mining and mineral processing developments.
• Collaborate with experienced multidisciplinary engineering teams.
• Contribute to process optimisation, sustainability and improved project outcomes.
• Develop their career within a global organisation with a broad project portfolio.