Senior Thermal Processing Engineer

About the Company

MP Materials (NYSE: MP) is rebuilding American industrial capability for a new era of autonomy, robotics, and electrification. We are the only U.S. company with a fully integrated rare earth supply chain—from mining and refining to advanced metal and magnet manufacturing. Our products include both the critical materials used to make permanent magnets and the finished magnets themselves—enabling next-generation technologies in robotics, automation, aerospace, transportation, defense, and energy systems. These materials are the foundation of physical AI—the convergence of computation, movement, and control. We hire ambitious, mission-driven people who want to tackle complex challenges and shape the future of strategic industries. Our culture is rooted in teamwork, resiliency, and integrity, with a deep commitment to operational excellence and national purpose. MP is rapidly evolving from a materials producer into a leading U.S. manufacturer—and our people are driving that transformation.

About the Role

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.

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.

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.

Desired Qualities

• 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.

Working Conditions

Our facility sits at an elevation of 4,700 feet. Employees may be subject to extreme weather conditions when working in an outdoor setting (heat and cold, wind). Work is at an open pit mine or manufacturing/chemical plant setting, which may include exposure to moving mechanical parts, toxic chemicals, risk of electrical shock, explosives, fumes, or airborne particles.

Physical Demands

• Manual dexterity; sense of touch; sense of smell; speaking clearly; hearing-speech range; hearing – all ranges; seeing, reading and comprehensions; seeing – distant/near; depth perception; color vision.
• While performing the job responsibilities, the employee is required to talk and hear. The employee is often required to stand and use their hands and fingers, to handle or feel and to manipulate laboratory equipment.
• The employee is occasionally required to walk, reach with arms and hands, climb or balance, and to stoop, kneel, crouch or crawl.
• Vision abilities required by this job include close vision.
• Employees must pass a full-face respiratory fit test.
• Employees must be able to lift 50 lbs.
• Must be able to work in PPE level C.