Senior Process Engineer Jobs in Frederick, CO (NOW HIRING)

Job Summary

The Senior Process Engineer will play a key role in developing, testing, and optimizing DISA's innovative HPSA technology for minerals processing, tailings remediation, and resource recovery. This role involves heavy lab work supporting the future design and execution of process experiments, generating high-quality data, and providing engineering insights to advance commercialization across multiple market applications. The Senior Process Engineer will collaborate closely with internal teams, consultants, and strategic partners to support R&D, pilot campaigns, and field deployments. The successful candidate will thrive in a dynamic start-up environment, wearing multiple hats and contributing to many areas of business development.

Typical Job Duties and Responsibilities

       Manage a team of process engineers, along with providing mentorship to junior staff.

       Collaborate with laboratory managers on testing schedules, equipment maintenance, and safety procedures.

       Lead the design and execution of laboratory and pilot-scale process experiments to generate robust technical data and presentation of results.

       Preparation of process engineering deliverables for capital equipment orders, including PFDs, mass balance, process design criteria, P&IDs, control philosophy, Lead internal process engineering Research and Development initiatives

       Develop and optimize process parameters using data-driven experimental design (DOE) and statistical analysis.

       Collaborate with cross-functional teams to transition laboratory findings into scalable field and commercial applications.

       Provide input to commissioning, troubleshooting, and optimization of PLC-based systems and other process control hardware/software.

       Design and execute laboratory and pilot-scale test campaigns, generating robust data sets and comprehensive technical reports.

       Structure experimental designs across a variety of mineral and waste materials to validate process performance and scalability.

       Participate in customer engagements, site visits, and technical presentations to communicate process capabilities and results.

       Support continuous improvement initiatives, including safety, quality, and environmental performance in all process-related activities.

       Stay current with emerging trends and technologies in minerals processing, remediation, and resource recovery to drive innovation.

       Abide by all policies and procedures established by DISA.

• Attend and participate in all required safety trainings.
• Assist with any task required by the direct supervisor. 

Required Skills

       Strong understanding of mineral processing, and process engineering principles.

       Hands-on experience with laboratory testing methods, instrumentation, and sample analysis.

       Knowledge of process design, optimization, and troubleshooting in a lab-to-production environment.

       Familiarity with statistical process control (SPC), data analysis, and experimental design (DOE).

       Experience developing and validating process parameters using lab-scale testing.

       Understanding of safety protocols (MSHA, OSHA, EPA, or equivalent) and lab best practices.

       Familiarity with engineering software (e.g., Metsim, JKSimMet, MATLAB, Minitab, AutoCAD, or similar).

       Knowledge of scale-up from laboratory/pilot testing to full production processes.

       Experience with PFD, mass balance, P&ID, process design criteria, and control philosophy development

       Apply strong analytical and problem-solving skills to manage multiple projects effectively.

       Communicate clearly and professionally, both verbally and in writing, to collaborate with colleagues, stakeholders, and clients.

       Organize and prioritize tasks to meet deadlines while managing multiple projects.

       Collaborate effectively as part of a team, supporting shared goals and fostering positive relationships.

       Adapt to dynamic environments and identify solutions to challenges with flexibility and problem-solving skills.

       Maintain professionalism with high attention to detail, reliability, accountability, and accuracy in all work deliverables.

       Uphold and demonstrate DISA's Values of Dedication, Innovation, Sustainability, and Accelerate Change.

       Ability to follow safety protocols and maintain compliance with OSHA/MSHA and company safety standards.

       Be a valid U.S. citizen or legally authorized to work in the United States.

       Possess a valid driver's license with a clean driving record.

Physical Requirements

• Must be able to sit and/ or stand for extended periods of time.
• Must be able to lift up to 50 lbs. occasionally.
• Must be able to interact with people and technology while either standing or sitting.
• To best service our customers, all employees must be able to communicate face-to-face and on the phone with or without reasonable accommodation.
• Ability to travel up to 25%.
• Must be able to perform repetitive tasks such as typing.

DISA Technologies provides equal employment opportunities (EEO) to all employees and applicants for employment without regard to race, color, religion, sex, national origin, age, disability, or genetics. 

Requirements

Education/ Experience

       Bachelor's degree in Mechanical, Mining, Chemical, Metallurgical, or Minerals Processing Engineering (or equivalent discipline) required (advanced degree preferred).

       10+ years of experience in minerals processing, and operating lab equipment preferred but not required.

Benefits

About Us

Are you ready to be part of a team that is bringing revolutionary technology to the mining industry?

DISA Technologies is revolutionizing mineral recovery with our patented High-Pressure Slurry Ablation (HPSA) technology-an innovative solution that upgrades critical minerals from mined ore and legacy waste. Serving both the mining and remediation sectors, we recover valuable resources that power industry, strengthen energy independence, and restore contaminated sites to productive use. Our technology unlocks economic and environmental value, transforming how the world processes, remediates, and recycles essential mineral assets. 

Benefits

       Bonus Pool

       401(k) with matching up to 4%

       Health insurance

       Dental insurance 

       Vision insurance

       Life insurance

       Paid holidays

       Paid time off

       Professional Development