Senior Process Engineer

Lead the development, optimization, and scale-up of Alcoa's proprietary ASTRAEATM 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.

Every day is a new and exciting challenge at the Alcoa Technical Center in New Kensington, PA, just north of Pittsburgh. We develop new technologies with our Breakthrough Technologies team that has the potential to impact the life of millions of people and foster the sustainable footprint from Alcoa to the world. It was here where we developed the technology recently announced in partnership with Rio Tinto, called ELYSISTM, where we will produce aluminum with ZERO emission of greenhouse gases. In fact, we will actually be generating oxygen to our atmosphere during the aluminum production process– a revolution to the aluminum industry!

We are values led, vision driven and united by our purpose of transforming raw potential into real progress. Our commitments to Inclusion, Diversity & Equity include providing trusting workplaces that are safe, respectful and inclusive of all individuals, free from discrimination, bullying and harassment and that our workplaces reflect the diversity of the communities in which we operate.

As a proud equal opportunity workplace and affirmative action employer, Alcoa is dedicated to providing equal opportunities and equal access to all individuals regardless of a person’s gender, age, race, ethnicity, sexual orientation, gender identity, religion, nation of origin, disability, veteran status, language spoken or any other characteristic or status protected by the laws or regulations in the places where we operate.

If you have visited our website in search of information on U.S. employment opportunities or to apply for a position, and you require an accommodation, please contact Alcoa Recruiting via email at [email protected].

This is a place where you are empowered to do your best work, be your authentic self, and feel a true sense of belonging. Come join us and shape your career!

Your work. Your world. Shape them for the better.