Senior Process Engineer - US MMM

About the Role

Worley is a global professional services company of energy, chemicals and resources experts. We partner with customers to deliver projects and create value over the life of their assets, solving complex problems with integrated data-centric solutions from consulting and engineering through installation, commissioning, decommissioning, and remediation. This role focuses on process plant design, metallurgical performance, and integration with site infrastructure, supporting projects from early studies through detailed engineering and commissioning.

The successful candidate will plan, coordinate, and manage the design, procurement, construction, and commissioning of assigned large capital projects, ensuring client objectives are met or exceeded while providing strong HSE leadership. This position plays a key technical role in delivering safe, operable, and cost-effective process plant solutions in line with Worley’s Engineering Execution model. The role is primarily office-based in Mesa, Arizona.

Responsibilities

• Provide metallurgical and process engineering support for crushing, grinding, classification, flotation, leaching, thickening, filtration, and SX/EW circuits in line with project scope.
• Analyze metallurgical, operating, and plant performance data to identify process improvement, optimization, and debottlenecking opportunities.
• Review, interpret, and apply laboratory, pilot plant, and site metallurgical testwork data to flowsheet development, design criteria, and equipment selection.
• Develop and maintain the process design basis, including metallurgical criteria, recovery targets, throughput assumptions, operating philosophy, and design margins.
• Perform and validate metallurgical and process calculations, including mass balances, metal recoveries, energy and heat balances, and comprehensive water balances.
• Develop and maintain metallurgical and process simulation models (e.g., MetSim or equivalent) to support flowsheet evaluation, equipment sizing, optimization, and trade-off studies.
• Prepare, review, and support delivery of core process engineering deliverables including PFDs, P&IDs, metallurgical reports, calculation packages, equipment data sheets, and specifications.
• Collaborate with process engineers and multidisciplinary teams (mechanical, piping, electrical, instrumentation, IS/automation, civil, and structural) to deliver integrated and constructible designs.
• Provide metallurgical input to equipment sizing, package definition, vendor technical evaluations, and review of supplier data and documentation.
• Accurately mark up process and metallurgical designs and calculation updates to support drafting and document control activities.
• Ensure engineering deliverables align with project schedules, quality requirements, and EPCM execution frameworks.
• Review technical work prior to issue to verify accuracy, compliance with standards, and fitness for purpose.
• Support construction, commissioning, ramp-up, and performance testing through technical reviews, troubleshooting, and operational guidance.
• Provide remote and occasional site-based commissioning and operational support to resolve metallurgical and process-related issues.
• Assist in developing commissioning plans and performance testing criteria for metallurgical and process systems.
• Identify, assess, and support mitigation of process-related technical, operational, and execution risks.
• Prepare clear and concise metallurgical reports, technical memoranda, performance summaries, and study documentation.
• Develop and maintain metallurgical accounting systems and reconciliation models to support design validation and operational assessments.
• Ensure technical documentation is reviewed, approved, and issued in accordance with quality management systems.
• Participate in HAZID, HAZOP, and process risk assessments, providing metallurgical input to hazard identification and mitigation recommendations.
• Ensure metallurgical designs and operating philosophies comply with safety, environmental, statutory, and regulatory requirements.
• Adhere to company engineering procedures, technical standards, quality plans, and safety policies.
• Liaise with project managers, discipline leads, and stakeholders to align metallurgical scope with project objectives, scope, schedule, and budget.
• Identify and manage risks associated with process design, metallurgical performance, equipment selection, and infrastructure interfaces.
• Support management of schedule, cost, quality, and scope for assigned metallurgical and process engineering activities.
• Conduct all client and stakeholder interactions in a professional, constructive, and respectful manner.
• Communicate technical issues, design intent, and project progress clearly with internal and external stakeholders.
• Coordinate with client and third-party discipline engineers to ensure compliance with project requirements and specifications.
• Support relationship development and Worley brand representation through technical excellence and collaborative engagement.
• Participate in site walkdowns, project meetings, design reviews, and incorporation of review comments.

Requirements

• Bachelor’s degree in Metallurgical Engineering, Mineral Processing, Chemical Engineering, or equivalent.
• 10+ years of Mining, Minerals & Metals industry experience with strong exposure to metallurgical process plants.
• Proven experience delivering process engineering in an EPCM/Engineering Services environment across conceptual studies, PFS, FS, detailed engineering, and commissioning support.
• Strong understanding of process plant infrastructure interfaces and utilities.

Preferred Qualifications

• Experience in base metals and/or copper processing circuits.
• Exposure to large-scale concentrators, hydrometallurgical, or metallurgical processing facilities.
• Experience supporting NI 43-101 / SK-1300 study inputs (process sections).
• Site or operational experience, including familiarity with mining safety and environmental requirements (MSHA certification is advantageous).

Skills

• Excellent verbal and written communication skills, with the ability to interact effectively with diverse clients and stakeholders.
• Strong analytical and problem-solving abilities to address complex technical and operational challenges.
• Demonstrated leadership in managing critical projects with a focus on safety, efficiency, and value optimization.
• Ability to innovate and develop new processes or technologies to improve operational efficiency and environmental sustainability.

About Worley

We’re building a diverse, inclusive, and respectful workplace where everyone feels they belong, can bring themselves, and are heard. Our focus is on a values-inspired culture that unlocks brilliance through belonging, connection, and innovation. We’re reskilling our people, leveraging transferable skills, and supporting the transition of our workforce to become experts in today’s low-carbon energy infrastructure and technology. Whatever your ambition, there’s a path for you here.