POSITION OVERVIEWThe Senior Process Control Engineer is responsible for the design, implementation, optimization, and support of process control and automation systems across concentrator operations. This role provides engineering support throughout the project lifecycle, from conceptual design and system development through commissioning and startup, ensuring reliable, safe, and efficient operation of plant control systems.
Working closely with Operations, Maintenance, Engineering, and Control Room personnel, the Senior Process Control Engineer serves as the technical lead for process automation, control strategies, and industrial network infrastructure. The role drives continuous improvement initiatives, develops advanced process control solutions, and ensures control systems support safe, reliable, and efficient plant performance.
POSITION RESPONSIBILITIES- Safety & Compliance: Promote a strong safety culture and ensure compliance with MSHA regulations, site safety standards, and company policies.
- Safety Leadership: Support safe work practices by verifying employees and contractors are properly trained, qualified, and following established procedures.
- Process Control Systems: Design, develop, modify, and maintain Programmable Logic Controller (PLC), Human Machine Interface (HMI), and Supervisory Control and Data Acquisition (SCADA) applications supporting concentrator operations.
- Automation Engineering: Develop control strategies for crushing, milling, flotation, filtration, and other mineral processing systems to improve reliability, efficiency, and production performance.
- Advanced Process Control: Develop and implement advanced control algorithms and determine the appropriate application of advanced versus conventional control strategies.
- Control System Standards: Develop equipment control modules, control philosophies, technical standards, engineering documentation, and implementation guidelines using industry best practices.
- Systems Architecture: Design and maintain process control system architecture, including industrial networks, wireless communications, firewalls, and supporting infrastructure.
- Technology Development: Evaluate emerging automation technologies and develop long-term technology roadmaps to support future operational requirements.
- Project Engineering: Develop project scopes, cost estimates, schedules, and technical specifications for capital and operating projects.
- Project Support: Provide engineering support during project planning, installation, commissioning, startup, and system optimization activities.
- Troubleshooting & Optimization: Diagnose and resolve process control, automation, and network issues while supporting continuous improvement initiatives throughout plant operations.
- Technical Leadership: Provide technical guidance and mentoring to Control Room Technicians and plant personnel on process control systems and automation technologies.
- Cross-Functional Collaboration: Work closely with Operations, Maintenance, Engineering, and contractors to improve plant reliability, equipment performance, and operational efficiency.
- Perform other duties as assigned.
POSITION REQUIREMENTSRequired- Bachelor's degree in Electrical Engineering, Mining Engineering, Metallurgical Engineering, Chemical Engineering, Civil Engineering, or a related engineering discipline.
- Minimum eight (8) years of experience designing, implementing, and supporting industrial control systems within mining or heavy industrial operations.
- Minimum eight (8) years of experience with the design and safe installation of process control systems in mining environments.
- Strong knowledge of Allen-Bradley PLC platforms, GE control systems, Wonderware, and Wonderware Historian.
- Experience programming and supporting PLC, HMI, SCADA, and industrial control systems.
- Experience with concentrator processes, including crushing, milling, flotation, and filtration operations.
- Strong understanding of industrial networking, wireless communication systems, and cybersecurity fundamentals for process control environments.
- Ability to develop process control architectures and automation strategies based on operational requirements.
- Ability to develop advanced control algorithms and determine appropriate application of advanced versus conventional control strategies.
- Experience developing technical standards, implementation guidelines, and engineering documentation.
- Experience developing project cost estimates, scopes of work, and project schedules.
- Proficiency with Microsoft Office applications, including Outlook, Excel, Word, and PowerPoint.
- Strong troubleshooting, analytical, and problem-solving skills.
- Strong interpersonal, communication, and leadership skills.
- Valid driver's license or ability to obtain a valid Arizona driver's license.
- Ability to read, write, speak, and understand English.
WORK ENVIRONMENT / PHYSICAL DEMANDS- Combination of office and field work in an active mining and mineral processing environment.
- Approximately 50% office work and 50% field work.
- Frequent exposure to noise, dust, vibration, moving equipment, and varying weather conditions.
- Walk and work on uneven ground and throughout operating plant areas.
- Climb stairs, ladders, and access elevated work areas.
- Kneel, crawl, stoop, bend, and squat while performing inspections and troubleshooting activities.
- Work in confined spaces when required.
- Wear all required personal protective equipment (PPE).
- Safely work around operating process equipment, electrical systems, and mobile equipment.
All candidates will be required to complete a pre-employment medical exam, drug and alcohol test, and background check. All positions require a pre-placement physical examination to ensure candidates are 'fit for duty'. Additional training and/or testing may be required. Capstone maintains a drug and alcohol-free workplace.
