Process Engineer- Electrolysis – Up to $110,000 – Fort Worth, TX

The Role

Do you have deep expertise in electrochemistry and want to play a role in shaping the future of U.S. manufacturing? Are you looking for a position where your technical skills directly support a critical national mission? If so, we have an exciting opportunity for you.

Exegistics are seeking a hands-on Process Engineer – Electrolysis to join our team in designing and building a state-of-the-art facility for metals, alloys and magnets. This role is central to our mission of restoring the rare earth supply chain within the United States. You will focus on molten salt electrolysis, the first stage of our manufacturing process, and work closely with management, quality, EHS, and maintenance teams to ensure success.

If you are eager to apply your electrochemistry expertise to molten salt electrolysis and help build a facility that strengthens the U.S. rare earth supply chain, we want to hear from you—apply today!

Key Responsibilities:

• Participate in equipment specification, design reviews, and commissioning of electrolysis lines
• Provide technical training and support to operators and technicians
• Contribute to EHS risk assessments, HAZOP studies, and compliance requirements
• Evaluate raw materials for plant performance and product quality
• Track KPIs to achieve high yield, consistent product quality, and minimal EHS impacts
• Supervise and improve quality control procedures
• Investigate and resolve issues within molten salt electrolysis and subprocesses
• Drive continuous improvement initiatives to reduce costs and eliminate waste
• Contribute to projects advancing rare earth electrolysis technology
• Prepare detailed technical reports, presentations, and documentation for intellectual property and patents
• Collaborate with procurement, vendors, maintenance, and cross-functional teams

The Person

• BS degree in Metallurgy/Materials Science, Chemical Engineering, Chemistry, or related field.
• 5+ years’ experience in electrochemistry with industrial scale processes and equipment.
• Knowledge and experience in gathering and tracking process control information for SPC.
• Problem solving experience (FMEA, 8D, A3, Root Cause Analysis etc.).
• Valid Driver’s License and good driving record are required to drive company vehicles on property.
• Deep technical knowledge of electrochemistry in general, and rare earth molten salt electrolysis.
• Knowledge of downstream processes, particularly alloying and casting.
• Experience with SAP.
• Ability to identify and solve problems and convince others (management down to operators) that your solution is the right one.
• Experience with programming, and process control operations; COMSOL Multiphysics, CFD, MATLAB, Python, Mini -Tab, AutoCAD /SolidWorks.

Desired Qualities:

• Deep technical knowledge of electrochemistry in general, and rare earth molten salt electrolysis.
• Knowledge of downstream processes, particularly alloying and casting.
• Experience with SAP.
• Ability to identify and solve problems and convince others (management down to operators) that your solution is the right one.
• Experience with programming, and process control operations; COMSOL Multiphysics, CFD, MATLAB, Python, Mini -Tab, AutoCAD /SolidWorks.

Contact information

Darren Sessom