Senior process engineer • calgary ab
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Job Purpose
The Advanced Process Support Engineer extends the reach of the Pumps, Cyclones, Valves & Knelson (PCV) Sales and Site Support teams into deeper mineral processing questions at customer operations. Where our Field Service teams focus on mechanical installation and maintenance; APS focuses on how PCV equipment performs within the process: classification efficiency, gravity recovery, circuit balance, as well as pump and cyclone interaction. The role works on site at mine operations across the assigned region, running surveys and simulations, supporting commissioning and troubleshooting from a process perspective, driving adoption of digital products such as Krebs OSA, and turning process findings into performance improvements and commercial opportunities for FLS.
Responsibilities
Process support and optimization. Serve as the technical process resource for Sales and Site Support on grinding, classification, gravity concentration, and slurry transport circuits. Diagnose performance issues and recommend operating and equipment changes that improve throughput, recovery, and wear life.
Circuit surveys and sampling. Plan and execute plant surveys and sampling campaigns, including particle size analysis, density and flow measurement, and mass balancing, to establish baseline performance and quantify the impact of improvements.
Simulations and sizing. Use FLSmidth proprietary software to perform cyclone simulations, pump sizing, and circuit modeling in support of proposals, upgrades, and troubleshooting. Validate results against field data and feed learnings back to product line and applications engineering.
Commissioning and troubleshooting. Support commissioning of new PCV and Knelson installations from a process standpoint, confirming equipment is operating to design. Lead process-side troubleshooting of issues such as cyclone roping, bypass, poor separation, and pump-cyclone mismatch, working alongside Field Service Engineers on mechanical items.
Digital product support. Support deployment, configuration, and customer adoption of Krebs OSA and other PCV digital and monitoring products. Interpret the data these tools generate and translate it into actionable recommendations for site teams.
Gravity concentration (Knelson). Support Knelson gravity concentrator applications, including gravity recoverable gold (GRG) assessment, circuit design review, performance audits, and optimization of existing installations.
Sales support. Partner with the sales team to identify upgrade and competitor-displacement opportunities, build technical value cases backed by survey and simulation data, and support technical proposals and customer presentations.
Customer training. Deliver process-focused training to plant metallurgists and operators on the performance, operation, and optimization of PCV products and digital tools.
Reporting and knowledge sharing. Prepare clear, professional survey, commissioning, and site reports documenting findings and recommendations. Share field learnings with Site Support, Applications Engineering, and product line teams.
Qualifications
Education. Bachelor’s degree in Mineral Processing, Metallurgical, or Chemical Engineering, or a closely related field.
Experience. 3 to 5 years minimum of total experience in mineral processing, with time as a plant metallurgist or in a similar operations-facing process role strongly preferred.
Process knowledge. Solid working knowledge of comminution circuits, slurry transport, and plant performance metrics.
Gravity concentration. Experience with gravity concentration circuits, ideally Knelson concentrators, is a strong asset.
Surveys and data. Hands-on experience planning and running plant surveys, sampling, and mass balancing, with strong data analysis skills in Excel. Experience with process modeling software (JK Sim, etc) preferred. Training on FLSmidth proprietary sizing and simulation software will be provided.
Digital aptitude. Comfort working with process data, instrumentation, and digital monitoring platforms; experience with online analytics or process control systems is a plus.
Equipment familiarity. Working understanding of slurry pumps, hydrocyclones, valves, and gravity concentrators from an operational perspective. Hands-on mechanical expertise is not required.
Communication. Able to work independently, communicate clearly with plant metallurgists, operators, and sales teams, and represent FLSmidth professionally on site.
Travel. Comfortable with frequent travel, expected at 50% to 75% across Canada.
Language. Fluency in English is mandatory. Additional fluency in French preferred.
Competencies and mindset
Curious, analytical problem-solver who connects equipment performance to process outcomes
Customer-focused, credible with site metallurgists and plant management alike
Comfortable working independently in remote and demanding site environments
Commercially aware, able to turn technical findings into a clear customer value case
Committed to a safety-first culture on every site
What we offer
Competitive pay with performance-based incentives
RRSP matching program
Full health and dental benefits
Generous time off (vacation, sick leave, flexible start/stop)
Long-term stability with a company that has been around for 140+ years
Opportunities for technical training, advancement, and growth
Development and training within a respected global OEM company
Employee Assistance Program for employees and immediate family
We offer all employees access to a dedicated recognition platform, empowering you to celebrate achievements, share appreciation and stay connected globally.
