Process Project Engineer

Company DescriptionAggrePlex focuses on sustainable innovation by producing ground glass pozzolan derived from recycled glass waste. Dedicated to reducing the environmental impact of cement production and glass disposal, AggrePlex uses cutting-edge technology for glass collection, cleaning, sorting, and processing. By integrating advanced Microtec mills and classification systems, the company contributes to environmental conservation while developing eco-friendly solutions. AggrePlex's mission is to lead the way in sustainable product development and resource recycling.Role DescriptionThis is a full-time, on-site role based in LOCATION for a Process Project Engineer. The Materials Processing Engineer is responsible for the end-to-end transformation, qualification, and performance optimization of raw and waste-derived materials within AggrePlex/Microtec processing environments. This role is focused on converting variable, non-homogeneous feedstocks—particularly glass, silica, and mineral streams—into high-performance, engineered products through advanced mechanochemical processing, ultra-fine micronization, and classification systems. The position ensures materials meet strict engineering specifications, regulatory requirements, and commercial performance standards while supporting safe, efficient, and scalable operations.This role is critical to scaling AggrePlex’s platform as a repeatable, financeable solution for low-carbon cement and concrete marketsKey Responsibilities1. Raw Material Qualification & Feedstock ManagementEvaluate incoming raw and waste-derived materials (glass, silica, minerals, metals, and composites) for composition, contamination, variability, and conformance to API, ASTM, ASME, ISO, and project-specific standards.Reverse engineer feedstock characteristics to determine optimal processing pathways and performance potential.Assess cullet quality, batch chemistry, and impurity profiles, including organics, CSP, and non-glass contaminants.Review and validate MTRs, COAs, and vendor certifications to ensure traceability and compliance.Develop strategies for handling variable and non-homogeneous feedstocks to ensure consistent downstream processing and product quality.2. Advanced Materials Processing & System IntegrationSet up, operate, and optimize AggrePlex/Microtec processing systems, including cleaning, drying, micronization (UTM TurboMills, Jet Mills), air classification (HTS systems), and integrated grinding/classification circuits.Adjust and control key process parameters (feed rate, air flow, temperature, pressure, rotor speed, classification cut points) to achieve precise particle size distribution (PSD) and performance targets.Integrate multiple unit operations into cohesive, high-efficiency processing lines, including conveying, dust collection, and material handling systems.Monitor real-time process data and proactively intervene to prevent deviations, inefficiencies, or product quality issues.Support fabrication, installation, and commissioning of processing systems in EPC and manufacturing environments.3. Quality Control, Testing & Material PerformanceDesign, validate, and continuously optimize processing systems to ensure consistent production of high-quality pozzolanic materials. Conduct comprehensive mechanical, physical, and chemical testing to evaluate and control product performance, including particle size distribution (PSD), loss on ignition (LOI), pozzolanic reactivity, and long-term durability characteristics, ensuring compliance with ASTM standards and performance specifications.Perform or oversee NDE/NDT methods (UT, RT, MT, PT) where applicable for system components and fabricated equipment.For glass-derived products: evaluate fineness, surface activation, amorphous content, and consistency of final SCM products.Ensure all materials meet ASTM (e.g., C618, C311, C1567) and other relevant specifications.Maintain rigorous QA/QC protocols to ensure repeatability, traceability, and compliance with project requirements.4. Process Optimization & Continuous ImprovementAnalyze operational and production data to improve throughput, reduce waste, and enhance product performance.Apply Lean, Six Sigma, and root cause analysis methodologies to eliminate bottlenecks and variability.Optimize milling efficiency, classification accuracy, and system energy consumption.Recommend improvements to processing configurations, equipment selection, and system layouts.Drive innovation in mechanochemical activation and particle engineering to enhance SCM performance and value.5. Equipment Reliability & Operational SupportPerform routine inspections and support maintenance of critical processing equipment, including mills, classifiers, dryers, conveyors, and filtration systems.Identify wear patterns, contamination risks, and calibration issues that could impact system performance or product quality.Collaborate with maintenance and engineering teams on troubleshooting and root cause analysis.Ensure compliance with OSHA, API, and plant safety standards across all operations.6. Documentation, Reporting & EPC DeliverablesMaintain detailed records of material inputs, processing conditions, and product outputs to ensure full traceability.Prepare and support EPC documentation, including ITPs, MDRs, PFDs, P&IDs, and turnover packages.Track material flows, yields, and waste streams to support operational efficiency and cost control.Generate technical reports supporting product validation, customer adoption, and regulatory compliance.7. Cross-Functional Collaboration & Commercial SupportWork closely with process engineers, materials scientists, QA/QC teams, and production personnel to ensure alignment across operations.Support vendor qualification, FATs, SATs, and system commissioning activities.Provide technical expertise to support customer trials, mix design development, and field validation.Contribute to commercialization efforts by translating technical performance into practical, scalable solutions.QualificationsEducation & ExperienceBachelor’s degree in Materials Science, Mechanical Engineering, Chemical Engineering, or related field.Proven experience in waste recycling, circular material systems, and reverse engineering of material processes—particularly involving glass, silica, and mineral-based feedstocks.Background in EPC, industrial processing, or advanced manufacturing environments preferred.Demonstrated ability to convert variable waste streams into consistent, engineered, value-added products.Familiarity with API, ASME, ASTM, ISO, NACE, and related industry standards.Technical SkillsDeep expertise in micronization, ultra-fine grinding, air classification, and separation technologies.Experience integrating complex processing systems into fully operational, high-performance production lines.Strong understanding of mechanochemical activation and particle engineering principles.Experience managing variable feedstocks to achieve tight PSD control, low LOI, and enhanced reactivity.Proficiency in QA/QC systems, including NDE/NDT methodologies and material performance validation.Familiarity with ERP/MES systems and production data analytics tools.Soft SkillsStrong analytical, problem-solving, and systems-thinking capabilities.Effective communicator with the ability to work across technical and operational teams.High level of adaptability in fast-paced, capital-intensive, and performance-driven environments.Results-oriented mindset with a focus on execution, reliability, and continuous improvement.