Process Engineer

Position Summary:

The Technical/Process Engineer is responsible for monitoring, optimizing, and improving the operations of delacquering and melting furnace processes to ensure safe, efficient, and high-quality aluminum production. This role leads process improvement projects, supports troubleshooting, ensures compliance with environmental and safety standards, and drives continuous improvement initiatives to maximize recovery rates, reduce costs, and minimize emissions. The engineer will collaborate with production, maintenance, and automation teams, supporting broader process engineering and reliability initiatives.

Key Responsibilities:

1. Process Monitoring & Optimization:

• Monitor furnace operations (delacquering and melting) to ensure process stability, efficiency, and safety.
• Analyze process data (temperature profiles, throughput, fuel/energy usage, emissions) and implement corrective actions.
• Optimize process parameters to improve yield, metal recovery, energy efficiency, and reduce operating costs.
• Support commissioning, upgrades, and new technology implementation for furnaces.
• Lead process improvement initiatives for delaquering furnaces, including sizing, throughput, emissions control, and burner performance.

2. Continuous Improvement:

• Develop and implement process improvement projects using appropriate methodologies (e.g., PDCA, Lean, Six Sigma).
• Identify and reduce process bottlenecks in delacquering and melting furnace operations.
• Improve refractory life, reduce metal losses, and enhance productivity through technical solutions.
• Gather and assess process data to reduce variation, improve capabilities, and optimize performance.
• Develop and maintain Power BI and Grafana reports for process and reliability tracking.
• Lead and engage employees in continuous improvement activities.

3. Safety & Environmental Compliance:

• Ensure all operations comply with safety regulations, environmental standards, and company policies.
• Support emissions monitoring and reduction strategies.
• Participate in risk assessments, safety audits, and incident investigations.
• Maintain and promote a safe work environment by observing and enforcing all applicable EHS rules, including 5S standards.

4. Technical Support & Troubleshooting:

• Provide hands-on technical support to operations and maintenance teams during furnace downtime or issues.
• Troubleshoot process deviations, product quality issues, and equipment malfunctions.
• Collaborate with suppliers, OEMs, and contractors on technical challenges.
• Work in a team environment with Maintenance, Production, Safety, and Plant Management to optimize asset reliability.
• Identify and manage asset reliability risks to avoid failures in production systems.
• Perform reliability assessments, downtime analysis, and drive defect elimination using Root Cause Analysis.

5. Reporting & Documentation:

• Maintain accurate records of process parameters, production reports, and improvement initiatives.
• Develop and update Standard Operating Procedures (SOPs) and work instructions.
• Train operators and shift engineers on best practices for furnace operation.
• Provide technical input for CAPEX projects, including equipment selection and layout planning.

Job Requirements:

• Bachelor’s degree in Chemical, Metallurgical, Materials, Mechanical, or Reliability Engineering (or related field) or equivalent work experience in lieu of education.
• 2–5 years of experience in furnace operations, aluminum recycling, foundry, or thermal process industry preferred.
• Strong knowledge of thermal processes, combustion systems, heat transfer, and emissions control.
• Experience with process simulation, data analysis, and continuous improvement tools.
• Familiarity with SAP PM or other CMMS, Power BI, and data analytics tools.
• Strong problem-solving, analytical, and communication skills.
• Proficient in Microsoft Office and process monitoring/control software.
• Must be able to work cohesively in a team environment.
• Excellent communication, coaching, and collaboration abilities.
• Experience with SEM/EDS, PoDFA, Alscan, and other melt quality tools is a plus.

Physical and Work Environment Demands:

• Work is mostly performed in a climate-controlled office setting but will also require presence on the plant floor with exposure to substantial heat, loud noises, fumes, and airborne particles.
• Occasional travel, including international travel, may be required (<25%).
• Physical demands include routine work in a heavy industrial environment, with appropriate PPE provided.

Additional Information:

Hydro Aluminum Metals is committed to safety, care, courage, and collaboration. We value diversity and encourage all qualified candidates to apply. Hydro Aluminum Metals USA, LLC is an Equal Opportunity Employer where all phases of employment are based strictly upon the qualifications of the individuals as related to the work requirements of the position. This policy is applied without regard to race, sex, sexual orientation, gender identity, religion, national origin, ancestry, age, disability, veteran status, marital status or any other category protected by law. Reasonable accommodations may be made to qualified individuals with disabilities to perform the essential functions of the job.