U.S. Silica Company · 12 hours ago
Sr. Process Engineer
United States
Full-time
Remote
Senior Level
7+ years expU.S. Silica Company is a leading producer of industrial minerals essential to modern life. The Sr. Process Engineer is responsible for front-end process design, equipment selection, and project development for silica, clay, and diatomaceous earth processing facilities, focusing on optimizing processes and ensuring safe and efficient operations.
ManufacturingMineralMining
Responsibilities
Responsible for front-end process design, equipment selection, and project development for silica, clay, and diatomaceous earth processing facilities. Scope includes designing and selecting equipment for dust collection systems, water transfer systems, milling, drying, crushing, screening, and classification circuits
Develop full FEL1/FEL2 project estimates, scopes of work, design criteria, and technical assumptions. Create mass balances, equipment lists, and process flow diagrams (PFDs)
Conduct trade‑off studies, support economic evaluations, and contribute to project justification and capital approval packages
Identify and evaluate productivity and cost‑reduction opportunities across U.S. Silica operations, partnering with CI and operations teams to implement improvements that increase process yield, boost throughput, enhance operating efficiency, reduce costs, and establish best practices
Provide hands‑on troubleshooting and optimization support at operating plants
Lead plant trials, performance audits, and process improvement initiatives. Support commissioning and startup of new or modified systems
Collaborate closely with operations, maintenance, EHS, and project teams to ensure safe, reliable, and sustainable performance
Track and monitor key productivity metrics to assure plants operate per design conditions, projects deliver on forecast goals / expectations, and to help identify further opportunities
Provide technical leadership and mentorship to plant engineers and technical staff as required
Document work in a structured manner to ensure Change Management is captured and conveyed in updated operating procedures, drawings, etc. Capture Best Practices so that they can be shared and implemented across sites
Ensure that all plant upgrades and installations of equipment are properly engineered to fully integrate within existing sites and achieve designed functionality. Interface with vendors, consultants, and contractors to achieve specified designs
Work with operating sites to define and assess mechanical integrity of process equipment and infrastructure to develop a replacement timeline for capital budgeting. Provide technical leadership and mentorship to plant engineers and technical staff
Identify and respond to opportunities to improve safety, environmental compliance, throughput, quality, costs, housekeeping, and employee commitment
Assist in prioritization of improvement needs while developing and implementing improvements
Qualification
Required
Bachelor's degree in Chemical, Process, Mechanical Engineering, Metallurgical, Mining Engineering or related field
Lean, Six Sigma, or continuous improvement training
Experience should include a minimum of 7 years in mineral processing or bulk solids handling
Strong experience in designing dust collection ducting and air systems
Proven experience with water transfer and pumping systems
Hands-on experience with mills, dryers, cyclones, screens, crushers, and pumps
Demonstrated experience independently developing FEL 1 and FEL 2 process designs, scopes, and cost estimates
Must have a proven record of accomplishment in a manufacturing culture focused on safety, reliability, and process improvement
Ability to interpret documents such as safety rules, operating and maintenance instructions, engineering drawings and procedure manuals and write routine reports and correspondence
Ability to speak effectively before groups of customers or employees of organization
Develop strategies to achieve organizational goals; Understands organization's strengths & weaknesses; Analyzes market and competition; Identifies external threats and opportunities
Use feedback to modify designs and generate creative solutions
To perform this job successfully, an individual should have general knowledge of Spreadsheet and Word Processing software; Process simulation software; Project Management software; Accounting software; Order processing systems; Contact Management systems; Internet software; Inventory software; Manufacturing software
Follow all statutory, regulatory, and organizational procedures to protect the environment from hazardous waste exposure
Experience in silica, clay, or diatomaceous earth processing
Experience with high-temperature drying and pneumatic conveying systems
Familiarity with NFPA dust standards and industrial ventilation principles
Experience supporting multi-site operations
Company
U.S. Silica Company
U.S. Silica Holdings Inc. is a global performance materials company and is a member of the Russell 2000.
1001-5000 employees
Funding
Current Stage
Public CompanyTotal Funding
$1.1B2024-04-26Acquired
2023-03-23Post Ipo Debt· $1.1B
2012-02-01IPO
Leadership Team
Ivia Rocafort
Chief Financial Officer, Oil & Gas Business Segment
Jay Moreau
Executive Vice President & Chief Operating Officer
Recent News
Research and Markets
2025-04-29
EIN Presswire
2025-03-11
Company data provided by crunchbase