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

role is to

develop, validate, and industrialize a developing electrolysis processing pathway

that is essential for processes technical feasibility, commercial viability, and safe long‑term operation. Furthermore, to ensure the electrolysis process operates safely, reliably, and efficiently by providing senior‑level technical ownership, solving complex process problems, and leading improvements that optimize safety, quality, throughput, and cost.

About the Role:

- Serve as the technical owner for assigned electrolysis and/or R&D processes

- Monitor process performance, identify deviations, and lead root cause investigations

- Develop and implement process improvements to enhance safety, stability, productivity, quality, and cost performance

- Establish and maintain process control limits, operating standards, and best practices

- Lead complex troubleshooting efforts involving process upsets, quality excursions, or equipment interactions

- Apply statistical, metallurgical, and process engineering principles to diagnose issues

- Support production teams with real time technical decision making during abnormal conditions

- Act as a subject matter expert for assigned processes

- Lead continuous improvement initiatives using Lean, Six Sigma, or similar methodologies

- Support capital and expense projects by defining process requirements, reviewing designs, and supporting commissioning/start up

- Develop technical specifications, operating procedures, and control strategies for new or modified equipment

- Evaluate new technologies, raw materials, or process changes for operational fit

- Help lead process transfer from R&D to pilot to plant scenarios during technology advancement.

- Ensure all processes operate in compliance with EHS policies, regulatory requirements, and internal standards

- Lead or support hazard analyses, risk assessments, and Management of Change (MOC) activities

- Provide technical input for incident investigations and corrective actions

- Promote a strong safety culture through visible leadership and technical rigor

- Work closely with Operations, Maintenance, Reliability, Quality, and Automation teams

- Mentor and coach junior process engineers and technicians

- Provide technical training and knowledge transfer to operations personnel

- Communicate process performance, risks, and improvement plans to leadership

- Ability to work in industrial environments, including exposure to heat, noise, and production equipment

- Ability to occasionally travel to plant sites or vendors

- Participation in off hour or on call technical support as needed

What you can bring to this role:

- Bachelor’s degree in chemical engineering, Metallurgical Engineering, Materials Science, Mechanical Engineering, or a closely related engineering discipline

- Advanced degree (Master’s) or Professional Engineer (PE) license preferred but not required.

- 7–10+ years of progressive experience in manufacturing or smelting process engineering

- Demonstrated experience supporting continuous, high temperature, or heavy industrial operations

- Proven ability to independently lead troubleshooting process and improvement initiatives

- Experience working directly with operating crews in a plant environment

- Demonstrated technology scale up and/or plant start up is preferred but not required.

- Strong understanding of process control, mass and energy balances, and industrial data analysis

- Experience with process monitoring tools, statistical analysis, and manufacturing KPIs

- Familiarity with MOC, hazard analysis, and root cause problem solving methodologies

- Proficiency with standard engineering and data tools (e.g., Excel, process historians, SPC software)

- Demonstrated technical leadership without direct authority

- Strong communication skills with the ability to translate complex technical concepts into practical guidance

- Ability to prioritize work in a fast paced, operational environment

- Comfortable making data driven decisions under production constraints

What we offer:

- Competitive compensation packages, including pay-for performance variable pay, recognition and rewards programs, and stock-based compensation awards (3-year vesting schedule)

- Flexible spending accounts and generous employer contribution to the HSA

- 401(k), employer match up to 6%, additional employer retirement income contribution (no vesting period), 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)

About the Location

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 ELYSIS™, 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 gssrecruiting@alcoa.com.

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.