Senior Process Engineer

Shape Your World

At Alcoa, you will become an essential part of our purpose: to turn raw potential into real progress. The way we see it, every Alcoan is a work-shaper, team-shaper, idea-shaper & world-shaper.

The Senior Process Engineer develops, validates, scales, and industrializes the ASTRAEA electrolysis process from laboratory and pre-pilot operations at the Alcoa Technical Center (ATC) through a pilot deployment. The role provides senior-level technical ownership for safe, reliable, and efficient operation; translates ATC learning into a controlled technology package; and aligns process design, operating parameters, procedures, training, commissioning, and startup support across ATC and pilot facility.

About the Role

• Lead the development, optimization, and scale-up of Alcoa's proprietary ASTRAEA™ electrolysis technology from laboratory testing through pilot and commercial implementation.
• Provide technical support of process performance, including troubleshooting, root cause analysis, and continuous improvement initiatives to enhance safety, quality, reliability, and productivity.
• Establish and maintain critical process parameters, operating standards, control strategies, and technology packages to support successful scale-up and commercialization.
• Lead technology transfer activities between research, pilot, and operating facilities, ensuring successful commissioning, startup, training, and long-term operational readiness.
• Collaborate with cross-functional teams, engineering partners, suppliers, and plant personnel to solve complex technical challenges and drive project execution.
• Support process safety, risk management, and regulatory compliance through hazard assessments, management of change (MOC), and implementation of corrective actions.
• Mentor engineers and operations teams while providing technical leadership for pilot operations, process innovation, and future technology deployment across global sites.
• Travel approximately 30%, primarily to Alcoa facilities, for alignment, transfer, training, commissioning, and readiness.

What you can bring to this role

• Basic Qualifications
• Bachelor's Degree in a STEM discipline
• 7+ years of experience in process engineering within electrolysis, metals, manufacturing, chemical processing, or other heavy industrial environments.
• Proven experience developing, scaling, and implementing technologies from laboratory or pilot-stage testing through startup, commissioning, and commercial operation.
• Strong expertise in process optimization, troubleshooting, root cause analysis, process controls, data analysis, and continuous improvement methodologies.
• Preferred Qualifications
• Bachelor's degree in Chemical or Mechanical engineering
• Master's Degree and/or Professional Engineer license including 5+ years' experience in process engineering within electrolysis, metals, manufacturing, chemical processing, or other heavy industrial environments.

What we offer

• Competitive compensation packages, including pay-for performance variable pay, recognition and rewards programs.
• Flexible spending accounts and generous employer contribution to the HSA
• 401(k), employer match up to 6%, additional employer retirement income contribution, and a non-qualified deferred compensation plan
• 12 paid holidays per year.
• 15 days of paid vacation (pro-rated from hire date).
• Employee Assistance Program (EAP)

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