Process Modeling Engineer

About the role

Mariana Minerals is searching for a Staff Process Modeling Engineer to advance new refining methods for essential minerals. This role involves creating, validating, and refining heat and material balance models to support the design of innovative mineral refining facilities. You will act as a technical expert in process simulation, guiding projects from initial concept to commercial use. You will own the core process models that define the operational and economic viability of new mineral processing flows. This position requires a deep level of analytical rigor to translate complex mineralogy into predictive digital twins. You will be responsible for ensuring that models accurately represent real-world unit operations and constraints. The role demands collaboration with metallurgists, process chemists, and project engineers to align model assumptions with project goals. Your work will directly influence the design decisions that shape the future of mineral refining infrastructure.

Key facts

What you'll do

• Build steady-state and dynamic process models to establish heat and material balances for integrated mineral refinery systems.
• Automate the sizing of equipment like reactors, heat exchangers, and separators based on model outputs, linking models to engineering documents.
• Create and maintain process simulation databases, ensuring consistency between modeling assumptions, test data, and engineering deliverables.
• Calibrate and reconcile models using pilot or plant operational data to ensure accuracy and predictive capability.
• Conduct process optimization studies, focusing on energy recovery, recycle strategies, and material efficiency.
• Develop dynamic process models to validate PLC and DCS programming and optimize buffer sizing during design.
• Connect process models to CAPEX and OPEX estimation tools, automating technoeconomic model creation.
• Document modeling methods and results, providing clear technical communication for design reviews and regulatory submissions.
• Lead the development of process flow diagrams that reflect the latest understanding of mineral processing chemistry.
• Support the creation of detailed equipment specifications derived from model-driven performance requirements.
• Perform scenario analysis to evaluate the impact of feed variability on process performance and product quality.
• Assist in troubleshooting underperforming processes by comparing model predictions with field measurements.
• Coordinate with control engineers to ensure that dynamic model behavior aligns with control strategy objectives.
• Translate complex mineral processing phenomena into structured model logic that can be audited and verified.
• Serve as a technical authority during front-end engineering design (FEED) and detailed design phases.

Requirements

• Bachelor's degree or higher in Chemical Engineering, Mechanical Engineering, Process Engineering, Metallurgical Engineering, or a related engineering field.
• 8 or more years of experience developing and applying process simulation models for chemical processing, hydrometallurgy, mining, refining, or similar industrial systems.
• Expertise in one or more of the following process simulation tools: ASPEN Plus/HYSYS, SysCAD, OLI Studio/OLI Flowsheet, or METSIM.
• Strong understanding of mass transfer, heat transfer, thermodynamics, fluid flow, and reaction engineering.
• Experience developing material and energy balances for multi-step, integrated process systems.
• Solid grasp of chemical equilibria and phase behavior in aqueous and non-aqueous systems.
• Familiarity with data reconciliation, parameter fitting, and model validation using experimental or operational data.
• Ability to work independently and make sound technical decisions with minimal direct supervision.
• Strong written and verbal communication skills for conveying technical information to cross-functional teams.
• Willingness to adhere to established modeling standards and quality procedures without deviation.

Nice to have

• Competency with Python or MATLAB for model automation, data processing, and custom calculations.
• Experience integrating process modeling outputs into EPC deliverables such as PFDs, P&IDs, equipment datasheets, and control narratives.

Practical notes

• This is an on-site position.
• The role is based in San Francisco, requiring physical presence at the headquarters location.
• Travel may be required to visit project sites or partner facilities as needed for model validation.
• Candidates must be eligible to work in the United States without sponsorship.
• The position does not offer remote or hybrid work arrangements.
• All work activities must comply with company policies regarding data security and intellectual property.
• Deadlines for project milestones will be determined by engineering schedules and client requirements.
• Professional development opportunities may be available at the discretion of the hiring team.