{"id":1378615,"url":"https://alion.io/job/mp-materials-senior-thermal-processing-engineer","title":"Senior Thermal Processing Engineer","company":{"id":1808321,"name":"MP Materials","domain":"mpmaterials.com","url":"https://alion.io/company/mpmaterials","size_band":"501-1000","is_staffing_agency":false,"employer_type":"direct","is_intermediary":false,"listed_via":null,"ats_vendor":"ADP","truth_index":{"grade":"A","score":92,"open_postings":93,"ghost_share":0.043,"stale_share":0,"repost_share":0,"time_to_fill_p50_days":100,"computed_at":"2026-11-15T07:52:55Z"}},"role":"Industrial Engineering","role_family":"Industrial Engineering","seniority":"senior","employment_type":"full_time","work_mode":"on_site","remote_scope":null,"remote_scope_basis":null,"remote_working_hours":null,"hiring_geo_confidence":"structured","locations":["Mountain Pass, United States"],"countries":["US"],"hiring_countries":[],"hiring_countries_total":0,"salary":{"min":140000,"max":170000,"currency":"USD","period":"year","gross":null,"usd_annual":170000},"salary_estimate":null,"experience_years_min":10,"visa_sponsorship":false,"relocation_package":false,"has_equity":false,"technologies":[{"name":"Microsoft Office","optional":false},{"name":"Physical AI","optional":false}],"status":"live","first_seen_at":"2026-08-12T21:25:00Z","employer_posted_date":"2026-08-12","last_verified_at":"2026-11-15T06:08:41Z","board_verified":true,"closed_at":null,"days_open":94,"trust":{"level":"ok","repost_count":0,"flags":["company_stale"],"days_open":93},"description":"Company Overview:\nMP Materials (NYSE: MP) is rebuilding American industrial capability for a new era of autonomy, robotics, and electrification.\nWe 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.\nWe 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.\nPosition Overview\nThe 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. The role requires coordination with Process Engineers, Operations, Maintenance, Reliability, Electrical, Process Controls, contractors, and equipment vendors to prioritize work and successfully execute projects.\nPosition Responsibilities\nProvide technical support for the operation, optimization, and reliability of kilns, calciners, coolers, dryers, and associated rotating equipment, conveyance systems, and dust handling systems.\nLead projects involving process optimization, debottlenecking, equipment modifications, capacity improvement, and design upgrades.\nAnalyze equipment performance, including temperature, material flow, refractory design & performance, residence time, draft, combustion, heat transfer, vibration, motor load, and product quality.\nTroubleshoot buildup, plugging, refractory damage, overheating, vibration, misalignment, air leakage, and mechanical failures.\nWork with Process Engineers, Operations, Maintenance, Reliability, Electrical, and Process Controls to improve equipment performance and reliability.\nDevelop engineering calculations, equipment specifications, scopes of work, cost estimates, schedules, and technical evaluations.\nSupport Capital Project teams through detailed engineering, design reviews, procurement, construction, commissioning, and startup.\nReview and update PFDs, P&IDs, equipment layouts, datasheets, and engineering drawings.\nCoordinate vendors, contractors, equipment procurement, installation, commissioning, and performance testing.\nManage projects from concept and design through execution, startup, and closeout.\nPresent equipment performance, project status, risks, and recommendations to plant and senior management.\nEnsure all changes comply with safety requirements, engineering standards, and the Management of Change process.\nAny other tasks as directed by management.\nBasic Qualifications\nBachelor’s degree in mechanical, chemical, metallurgical, or a related engineering discipline.\nExperience with industrial kilns, rotary kilns, calciners, dryers, solids conveyance systems, baghouses, furnaces, or similar high-temperature equipment.\nExperience with rotating equipment such as gearboxes, bearings, drives, couplings, fans, blowers, and lubrication systems.\nExperience in mining, metallurgical processing, cement, chemical processing, petroleum, or another heavy industrial environment.\nStrong troubleshooting, equipment optimization, and project execution experience.\nUnderstanding of heat transfer, combustion, material flow, draft, thermal expansion, refractory systems, and mechanical reliability.\nAbility to read and develop PFDs, P&IDs, equipment drawings, specifications, and technical documentation.\nAbility to perform heat and mass balances, equipment sizing, throughput calculations, and technical evaluations.\nFamiliarity with plant control systems, PI Vision, SAP, and Microsoft Office applications.\nValid driver’s license.\nDesired Qualities\n10+ years’ experience in a related engineering, operations support role\nHands-on, safety-focused engineer who is comfortable working in the field.\nStrong project owner who drives work from initial concept through successful operation.\nAnalytical and detail-oriented problem solver who uses data and field observations to make sound engineering decisions.\nProactive self-starter with a strong sense of urgency and accountability.\nEffective communicator who works well with operations, maintenance, contractors, vendors, and management.\nMP Materials is Proud to be an Equal Opportunity / Affirmative Action Employer\nAll qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, disability, protected veteran status, or any other characteristic protected by law. Underrepresented groups/Women/Disabled/Veterans are encouraged to apply. Candidates whose disabilities make them unable to meet the position’s requirements will still be considered qualified if they can perform the essential functions of the job with reasonable accommodation.\nYour Right to Work - In compliance with federal law, all persons hired will be required to verify identity and eligibility to work in the United States and to complete the required employment verification document form upon hire.\nFor Assistance with Application - Alternative methods of applying for employment are available to individuals unable to submit an application through this site because of a disability. Contact Human Resources Department at 702-844-6111; dial 7 when prompted for HR;1700 South Pavilion Center Dr. 8th Floor, Las Vegas, NV 89135 to discuss reasonable accommodation.\nSafety Provision - Employees are responsible for following all company, industry and regulatory procedures and laws to ensure a safe work environment for themselves and the company. Employees must have a willingness to promote safety among the workforce, participate in Process Hazard Analysis procedures and Pre-Startup Safety Reviews.\n(PPE) Personal Protective Equipment is required when performing work in a mine, manufacturing, outdoor, or plant environment. Required PPE may include, but is not limited to, hard hat, hearing protection, safety glasses, safety footwear, respirator, rubber steel-toe boots, protective clothing, gloves, and any other protective equipment as required.\nWorking 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.\nPhysical 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. 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