Process Engineer
First seen by Alion on Oct 29, 2026.
SUMMARY:
We are recruiting a Process Engineer for a well-established mineral processing equipment and solutions provider. This is a permanent, client-facing role covering the full project cycle: front-end design, simulation, test work, site audits, sales support and commissioning.
It suits an engineer who enjoys variety — office-based design and modelling one week, test plant or client site the next.
POSITION INFO:
What you will do Front-end engineering and process design Develop process flowsheets for concept, pre-feasibility and feasibility studies, proposals and tenders. Compile mass and water balances from simulations, test work and client plant data. Prepare process design criteria, PFDs and equipment lists. Size and select equipment across comminution and mineral separation, working with OEM partners. Provide technical input to CAPEX\/OPEX estimates, performance guarantees and tender submissions. Take part in design reviews, HAZOPs and risk assessments, and hand designs over to project execution. Process simulation and modelling Build and calibrate Aggflow models of crushing and screening circuits. Run scenario and sensitivity analyses on feed variability, throughput and product specification. Maintain a controlled library of models, assumptions and equipment data. Test work and test plant Plan test work programmes, including sampling, test matrices and success criteria. Guide test plant operations and ensure QA\/QC on sample prep, testing and data capture. Interpret results and issue test work reports with flowsheet and equipment recommendations. Support the evaluation of new technologies and applications. Client site audits and optimisation Run process audits at client sites: sampling campaigns, surveys and mass balance reconciliation. Identify bottlenecks and losses, quantify their value, and present prioritised recommendations. Sales support Support the sales team from opportunity through to order award. Prepare technical proposals, process descriptions, datasheets and compliance schedules. Present flowsheets and test results to clients, and support technical negotiations. Commissioning and performance testing Prepare commissioning plans, control philosophies and start-up procedures. Support cold and hot commissioning on site and optimise ramp-up to design throughput. Plan and run performance tests and compile close-out reports. Train client operating and metallurgical staff. Knowledge development Author technical papers, case studies and conference presentations (e.g. SAIMM). Share knowledge through internal training, design guidelines and lessons-learnt records. What you need Qualification BEng \/ BSc in Chemical, Metallurgical or Mineral Process Engineering (or equivalent). ECSA registration (Pr Eng \/ Pr Tech Eng), or working towards it, is an advantage. Experience At least 5 years' process engineering experience in mineral processing, including front-end or study-phase design. Hands-on flowsheet development, mass balancing and equipment sizing across comminution and mineral separation. Aggflow or comparable simulation software (JKSimMet, Bruno, METSIM, LIMN). Planning and interpreting metallurgical test work; exposure to pilot or test plant operations. Plant operations, commissioning or process audit experience is an advantage. Skills Strong analytical and problem-solving skills with sound engineering judgement. Excellent technical writing and report compilation. Confident presenting to clients, OEM partners and internal teams. Able to turn test work and simulation data into practical, commercially sound recommendations. Advanced Excel, MS Office, and PFD drafting tools (Visio \/ AutoCAD). Well organised, able to juggle multiple projects and deadlines, and work independently. Willing to travel to sites and spend multiple days away from home.