Staff Process Modeling Engineer

About the role

Mariana Minerals is seeking a highly motivated Staff Process Modeling Engineer to support the development of next-generation refining processes for critical minerals. This role is essential in advancing the company's mission to supply critical minerals that are vital for modern energy, AI, and defense technologies. The successful candidate will be responsible for developing, validating, and optimizing heat and material balance models using advanced process simulation tools such as ASPEN Plus, HYSYS, SysCAD, OLI Studio, or METSIM. They will work closely with research and development teams, pilot operations, and project execution groups to translate laboratory and pilot plant data into , scalable process models. These models will inform the design and construction of innovative mineral refining facilities, enabling Mariana Minerals to lead in responsible mineral sourcing. The role also involves serving as a technical leader in process simulation, establishing modeling standards, mentoring junior engineers, and collaborating across teams to support process development from initial concept through to commercial deployment.

Key facts

What you'll do

• Develop comprehensive steady-state and dynamic process models to establish accurate heat and material balances for integrated mineral refinery systems, utilizing tools such as ASPEN, SysCAD, OLI, or METSIM.
• Automate equipment and process sizing calculations, including reactors, heat exchangers, filters, crystallizers, evaporators, and separators, by linking model outputs to datasheets and other engineering tools.
• Maintain and update process simulation databases, ensuring consistency and traceability between modeling assumptions, experimental data, operational data, and engineering deliverables.
• Calibrate models with pilot plant or operational data to improve model fidelity, ensuring predictive accuracy and reliability for process design and optimization.
• Conduct process optimization studies focused on energy and heat recovery, recycle strategies, and material efficiency improvements to enhance process performance and reduce costs.
• Develop dynamic process models to validate programmable logic controller (PLC) and distributed control system (DCS) programming, as well as to evaluate and optimize buffer sizing during the design phase.
• Link process models to capital expenditure (CAPEX) and operational expenditure (OPEX) estimation tools, automating technoeconomic analyses to support project feasibility and decision-making.
• Document modeling methodologies, assumptions, and results clearly and thoroughly, providing technical communication for design reviews, techno-economic assessments, and regulatory submissions.
• Collaborate with multidisciplinary teams to integrate process models into larger project workflows, ensuring alignment with engineering standards and project goals.
• Support process development activities from concept through pilot testing and into full-scale commercial deployment, providing technical guidance and expertise throughout the project lifecycle.
• Contribute to the continuous improvement of modeling standards, best practices, and tools to enhance efficiency and accuracy across projects.
• Assist in training and mentoring junior engineers and team members in process modeling techniques and software tools, fostering a culture of technical excellence and knowledge sharing.

Requirements

• Bachelor's degree or higher in Chemical Engineering, Mechanical Engineering, Process Engineering, Metallurgical Engineering, or a closely related engineering discipline.
• Minimum of 8 years of experience developing and applying process simulation models within chemical processing, hydrometallurgy, mining, refining, or related industrial process systems.
• Proficiency with at least one of the following process simulation tools: ASPEN Plus, HYSYS, SysCAD, OLI Studio, or METSIM.
• Deep understanding of mass transfer, heat transfer, thermodynamics, fluid flow, and reaction engineering principles relevant to mineral processing and refining.
• Proven experience in developing material and energy balances for complex, multi-step, integrated process systems.
• Strong knowledge of chemical equilibria, phase behavior, and thermodynamic modeling in aqueous and non-aqueous systems.
• Familiarity with data reconciliation, parameter fitting, and model validation techniques using experimental or operational data.
• Experience automating models and data processing using programming languages such as Python or MATLAB is highly desirable.
• Ability to link process modeling outputs into engineering deliverables like process flow diagrams (PFDs), piping and instrumentation diagrams (P&IDs), equipment datasheets, and control narratives.
• Excellent problem-solving skills, attention to detail, and the ability to communicate complex technical concepts clearly.
• Demonstrated ability to work collaboratively in multidisciplinary teams and manage multiple projects simultaneously.

Nice to have

• Experience with process automation and control system design, including PLC and DCS programming validation.
• Knowledge of technoeconomic modeling and cost estimation techniques relevant to mineral processing projects.
• Familiarity with regulatory standards and compliance requirements in mineral processing and refining industries.
• Prior experience working in fast-paced, collaborative engineering environments with cross-functional teams.
• Understanding of sustainability practices and environmental considerations in mineral processing projects.
• Exposure to project management methodologies and tools to support project delivery and stakeholder communication.

Skills & tools

• ASPEN Plus / HYSYS
• SysCAD
• OLI Studio / OLI Flowsheet
• METSIM
• Python or MATLAB (preferred)
• Data reconciliation and model validation techniques
• Process simulation database management
• Technical documentation and reporting skills

Practical notes

an on-site role based in Houston, TX, requiring the candidate to work at the company's location. The position involves close collaboration with R&D, pilot plant, and engineering teams to develop and implement scalable mineral refining processes. Candidates should have a strong background in process simulation, modeling, and process engineering, with a focus on chemical and mineral processing industries. Mariana Minerals values a culture of ownership, continuous improvement, automation, and knowledge sharing. The role offers an opportunity to contribute to innovative solutions that support the global energy transition and responsible mineral sourcing. Candidates should be prepared to engage in technical discussions, contribute to process development projects, and support the company's mission to the minerals supply chain through advanced software and automation.

About the company

Mariana Minerals is a software-first, vertically integrated minerals company focused on supplying the minerals critical to modern energy, AI, and defense technologies.