Lead Process Engineer - Rare Earth Metals & Magnet Production (Consultancy / Project Lead)

Location: Riyadh, Saudi Arabia (occasional travel required)
Reporting to: Programme Director / Project Lead

Project overview
The Kingdom of Saudi Arabia is executing an industrial transformation under Vision 2030 to expand domestic industrial capacity and capture greater value across strategic minerals value chains. Our client is establishing a pioneering industrial facility to process critical minerals and produce rare-earth products and permanent magnets. The facility will support growing industrial clusters and energy-transition technologies (EVs, wind power, and related applications), reinforcing Saudi Arabia's position as a regional hub for rare-earth processing and magnetics.

Role summary
We are seeking a highly experienced Lead Process Engineer to join the project team in a senior consultancy role. The incumbent will help finalize the feasibility and concept phase (Stage 1) and will prepare the RFQ packages required for FEED (Stage 2). This role requires deep technical expertise in rare-earth metals and magnet production processes, a track record of taking projects from concept through to FEED and commissioning, and strong stakeholder leadership.

Key responsibilities

• Lead technical development for process routes related to rare-earth extraction, separation, refining, alloying and permanent magnet production (e.g., NdFeB, SmCo, or other targeted magnet chemistries).
• Evaluate and compare process alternatives, technology readiness, and integration options to maximize value capture and export readiness.
• Define basis of design and produce technical specifications and scope for FEED packages and RFQ documents.
• Support project feasibility studies: mass/energy balances, material flows, reagent consumptions, utility requirements, and CAPEX/OPEX estimates.
• Identify critical technical risks (e.g., contamination, reagent availability, environmental and safety constraints) and propose mitigation measures.
• Provide input to plant layout, utilities, and integration requirements in collaboration with multi-discipline engineers.
• Support vendor assessment, technology due diligence and benchmarking.
• Coordinate with commercial, permitting, environmental, and HSE teams to ensure regulatory compliance and sustainable operations.
• Mentor and coordinate with multidisciplinary project team and external consultants

Requirements

Essential

• Bachelor's degree in chemical, Metallurgical, Materials or Process Engineering, or a relevant science discipline from a recognized university.
• Minimum 15-20 years' experience in industrial process development and plant delivery; demonstrable experience across feasibility, FEED, procurement/RFQ, and commissioning stages.
• Direct experience in rare-earth metals processing and/or permanent magnet manufacturing (or closely related hydrometallurgical/pyrometallurgical processes).
• Proven record of delivering industrial facilities from concept to commissioning or FEED delivery.
• Strong technical writing skills for RFQs, technical specifications, and feasibility reports.
• Excellent critical thinking, leadership and stakeholder-management skills.
• Comfortable working with multinational teams; fluent in English.

• Outcome-driven: prioritizes timely delivery and consistently meets cost, schedule and quality requirements

Desirable

• MSc or PhD in relevant discipline.
• Experience with rare earth separation technologies (e.g., solvent extraction, ion exchange, precipitation), alloy production, sintering, powder metallurgy, and magnetization processes.
• Experience in regulatory permitting, HSE for mineral processing, and international export controls relevant to critical minerals.
• Previous experience working in the Middle East or GCC region.

Benefits

• Opportunity to shape a strategic, high-impact national industrial program.
• Competitive consultancy remuneration (commensurate with experience)
• Riyadh-based role with travel as required.