Job Description

Shape Your World

At Alcoa, you will become an essential part of our purpose: to turn raw potential into real progress. The way we see it, every Alcoan is a work-shaper, team-shaper, idea-shaper & world-shaper.

The primary purpose of the Senior Raffinate Process Engineer is to develop, validate, and industrialize the raffinate processing pathway that is essential for Astraea’s technical feasibility, commercial viability, and safe long-term operation. Raffinate behavior directly affects cell stability, metal purity, by product generation, and the overall value proposition of the Astraea purification technology.

About the Role:

• Provide process engineering for raffinate experimentation at bench scale through pilot scale – this includes reviewing and analyzing existing information, making conclusions, articulating hypotheses, defining test plans, and executing test plans

• Define, schedule, monitor, and complete individual R&D testing by establishing project plans in consultation with supervisor and team members that meet the needs of the program

• Solve problems to the root cause, seeks and identifies opportunities, and implements innovative solutions within defined boundaries

• Collaborate with modeling scientists, metallurgists Alcoa employees and external consultants) to validate models with experimental results

• Provide functional guidance to laboratory technicians and other engineers/scientists

• Interface with external vendors and suppliers in conjunction with supervisor and team to get work scopes and timing for R&D work defined

• Working with other Alcoa engineers and external consultants, explore and evaluate uses and markets for raffinate products. This will include communication with potential customers both inside and outside the aluminum industry.

• Communicate progress and results through written technical reports, patents, oral presentations, and other publications

What you can bring to this role:

• Bachelor’s degree in Chemical Engineering, Metallurgical Engineering, Materials Science & Engineering, or a closely related discipline. Required

• Demonstrated knowledge in process engineering of chemical and/or metallurgical processes.

• Master’s degree in Chemical, Metallurgical, or Materials Engineering for roles with increased emphasis on experimental design, modeling collaboration, and pilot‑scale technology integration. Preferred

• 5-8 years, with a preferred 7-10 years of work experience in a process industry; dependent on education or work experience.

• Understanding of fluid flow, heat transfer, thermodynamics, and kinetics as related to molten metals processing.

• Experience in conducting development activities and experimentation in a laboratory to pilot-scale environment.

• Proficiency in designing and executing bench‑scale through pilot‑scale experiments.

• Ability to interpret complex datasets, derive conclusions, and iterate experimental hypotheses.

• Understanding of mass balance, multiphase behavior, and transport phenomena.

• Basic knowledge of analytical techniques (e.g., SEM/EDS, metallography) used to assess phases, deposits, and solidification structures.

• Understanding of alloy behavior is relevant to raffinate by‑products and impurity control.

• Competence in working with multidisciplinary teams including metallurgists, modelers, technicians, external vendors, and potential customers.

• Clear, structured communication for internal reviews, cross‑functional decision‑making, and external customer discussions.

• Hands-on work required: ability to apply chemical fundamentals and technology into practical solutions and applications

What we offer:

• Competitive compensation packages, including pay-for performance variable pay, recognition and rewards programs, and stock-based compensation awards (3-year vesting schedule)

• Flexible spending accounts and generous employer contribution to the HSA

• 401(k), employer match up to 6%, additional employer retirement income contribution (no vesting period), and a non-qualified deferred compensation plan

• 12 paid holidays per year.

• 15 days of paid vacation (pro-rated from hire date).

• Employee Assistance Program (EAP)

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About the Location

Every day is a new and exciting challenge at the Alcoa Technical Center in New Kensington, PA, just north of Pittsburgh. We develop new technologies with our Breakthrough Technologies team that has the potential to impact the life of millions of people and foster the sustainable footprint from Alcoa to the world. It was here where we developed the technology recently announced in partnership with Rio Tinto, called ELYSIS™, where we will produce aluminum with ZERO emission of greenhouse gases. In fact, we will actually be generating oxygen to our atmosphere during the aluminum production process– a revolution to the aluminum industry!

We are values led, vision driven and united by our purpose of transforming raw potential into real progress.  Our commitments to Inclusion, Diversity & Equity include providing trusting workplaces that are safe, respectful and inclusive of all individuals, free from discrimination, bullying and harassment and that our workplaces reflect the diversity of the communities in which we operate.   

As a proud equal opportunity workplace and affirmative action employer, Alcoa is dedicated to providing equal opportunities and equal access to all individuals regardless of a person’s gender, age, race, ethnicity, sexual orientation, gender identity, religion, nation of origin, disability, veteran status, language spoken or any other characteristic or status protected by the laws or regulations in the places where we operate. 

If you have visited our website in search of information on U.S. employment opportunities or to apply for a position, and you require an accommodation, please contact Alcoa Recruiting via email at gssrecruiting@alcoa.com. 

This is a place where you are empowered to do your best work, be your authentic self, and feel a true sense of belonging. Come join us and shape your career! 

Your work. Your world. Shape them for the better.