Process Engineer

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.

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.