DGM / Senior Manager - Process Engineering (Mauritania -Africa)

Role Summary:

The Processing Engineer will play a critical role in the Hematite Scram Project, which focuses on the recovery and beneficiation of low-grade hematite ores and scram (waste) material. The role involves designing, developing, and optimizing mineral processing systems with a focus on sustainability, throughput efficiency, and cost-effectiveness. The engineer will support the project from concept development through commissioning and stabilization of the plant.

Key Responsibilities:

Process Design and Development

• Develop detailed Process Flow Diagrams (PFDs) and Piping and Instrumentation Diagrams (P&IDs) for the processing of hematite and scram ore.
• Select appropriate beneficiation technologies based on the characteristics of the ore (e.g., dry/wet screening, magnetic separation, gravity separation).
• Conduct laboratory-scale and pilot-scale metallurgical test work in collaboration with third-party laboratories.
• Perform material and water balance calculations and generate process simulations using various software tools.
• Work closely with consultants and test laboratories to define design parameters for key process equipment, including crushers, screens, Grinding, DMS, Flotation Circuit and Tailing Managements.

Project Engineering and Execution Support

• Provide technical input during EPC tendering, vendor selection, and detailed engineering.
• Collaborate with Geologists, Mechanical, electrical, civil, and instrumentation teams to ensure process needs are incorporated in detailed designs.
• To participate in HAZOP studies, design reviews, and risk assessments.
• To support the construction and commissioning team in verifying process equipment installation and trial runs.
• To monitor ramp-up performance and troubleshoot operational challenges during the stabilization phase.

Process Optimization & Monitoring

• Monitor real-time data and production KPIs to identify process inefficiencies.
• Analyse throughput, recovery, product grade, and yield performance; implement corrective measures.
• Introduce process control schemes and automation tools for consistent operation.
• Evaluate water and energy usage across the plant and propose optimization initiatives. Develop Water Balance Projection based on Baseline datasets which might require in other Global greenfield Project (wherever required)

Compliance and Safety

• To ensure adherence to industry safety standards (e.g., OSHA, MSHA, ISO, DGMS).
• To support environmental compliance efforts related to tailings, effluent discharge, and dust control.
• To participate in incident investigations and implementation of corrective/preventive actions (CAPA).

Documentation & Reporting

• To prepare technical reports, operating manuals, SOPs, and process datasheets.
• To generate daily/weekly/monthly reports on plant performance, variances, and recommendations.
• To train operations staff on process parameters and standard operating procedures.

Preferred candidate profile

• B.E. / B. Tech or M.E. / M. Tech in Mineral Processing, Metallurgical Engineering, Chemical Engineering, or equivalent.
• 10 to 20 years of experience in mineral processing, particularly in iron ore beneficiation (hematite).
• Proven experience with scram (waste) handling and recovery systems is highly desirable.
• Experience with commissioning and early-stage plant operations is an added advantage.
• Proficient in process simulation software (e.g., METSIM, HSC Chemistry, JKSimMet or similar).
• Proficiency in AutoCAD / SolidWorks (for equipment layout review)
• Knowledge of instrumentation and process control systems (e.g., SCADA, DCS)

Certifications (Optional):

• Six Sigma Green Belt / Lean Manufacturing
• Project Tracker Software (Primavera Software Usage)
• ISO 9001:2015 QMS Awareness
• NEBOSH / Safety Certification (for site-based roles)Role & responsibilities