Job Specification: Hydrometallurgist

🎯 Role Definition

A Hydrometallurgist is a specialized engineer who designs, manages, and optimizes processes that use aqueous chemistry to extract and purify metals from ores, concentrates, recycled materials, and other sources. At its core, this role is about unlocking value from materials by dissolving desired metals into a solution and then selectively recovering them. This field is critical for producing essential metals like copper, gold, nickel, cobalt, zinc, and lithium, and is at the forefront of the sustainable materials revolution, particularly in battery recycling and the processing of critical minerals for green technologies. The Hydrometallurgist is a unique blend of a chemical engineer, a materials scientist, and a process detective, working in environments from R&D labs to large-scale industrial plants.

📈 Career Progression

Typical Career Path

Entry Point From:

Graduate Chemical Engineer / Metallurgical Engineer
Process Engineer-in-Training (EIT)
Laboratory Metallurgist or Technician

Advancement To:

Senior or Principal Hydrometallurgist
Process Superintendent or Technical Manager
R&D or Innovation Manager

Lateral Moves:

Project Manager (Capital Projects)
Environmental Engineer (Water Treatment/Remediation)
Technical Sales or Field Engineer (Chemicals or Equipment)

Core Responsibilities

Primary Functions

Design, execute, and meticulously analyze metallurgical test work programs, including leaching (atmospheric, pressure, heap), solvent extraction, ion exchange, and precipitation, to optimize metal recovery and product purity.
Develop and refine comprehensive process flowsheets (PFDs) and detailed piping and instrumentation diagrams (P&IDs) for new hydrometallurgical circuits or major plant expansions.
Provide daily, hands-on technical support to plant operations, actively troubleshooting process upsets, identifying bottlenecks, and implementing solutions for continuous improvement in recovery, cost, and efficiency.
Conduct and validate complex mass, water, and energy balance calculations for various hydrometallurgical unit operations to ensure process stability, predict plant performance, and support financial modeling.
Manage, interpret, and visualize large datasets from plant operations and laboratory analyses, utilizing statistical process control (SPC) to monitor Key Performance Indicators (KPIs) and drive data-informed decisions.
Author detailed technical reports, engineering studies, feasibility assessments, and Standard Operating Procedures (SOPs) to formally document findings, justify capital projects, and guide operational practices.
Lead or serve as a key technical contributor in Hazard and Operability (HAZOP) studies, Process Hazard Analyses (PHA), and Failure Mode and Effects Analyses (FMEA) to ensure the safe design and operation of chemical processes.
Evaluate, trial, and select new technologies, process equipment, and chemical reagents to enhance process performance, improve safety, and reduce overall operational expenditures.
Collaborate closely with project engineering and EPCM firms during the design, construction, and commissioning phases of new hydrometallurgical facilities, ensuring design intent is met.
Develop, implement, and manage robust metallurgical accounting systems to ensure the accurate and auditable tracking of metal units throughout the process, from feed to final saleable product.
Mentor and coach junior engineers, metallurgists, and plant operators, providing structured training on metallurgical principles, process control strategies, and critical safety procedures.
Oversee the technical direction of laboratory and pilot-plant scale testing campaigns, ensuring the generation of high-quality, scalable data and maintaining equipment integrity.
Model and simulate complex hydrometallurgical processes using specialized software (e.g., METSIM, HSC Chemistry, SysCAD) to evaluate process alternatives, optimize plant configurations, and de-risk investments.
Investigate and develop sustainable solutions for managing and treating process effluents, tailings, and other waste streams to ensure full compliance with environmental regulations and company standards.
Engage with external consultants, technology vendors, and academic research institutions to stay abreast of industry best practices, emerging trends, and innovative solutions.
Prepare, justify, and manage budgets for metallurgical projects, extensive test work programs, and departmental operational expenses, tracking costs and ensuring financial accountability.
Perform detailed techno-economic evaluations of process improvement initiatives or new projects, developing the business case for capital expenditure justification.
Champion a safety-first culture, ensuring all metallurgical activities, test work, and plant trials comply with company safety policies and governmental regulations.
Develop predictive models for process behavior based on ore mineralogy and feed chemistry (geometallurgy) to anticipate and proactively mitigate operational challenges related to feed variability.
Lead structured Root Cause Analysis (RCA) investigations for significant process deviations, environmental incidents, or equipment failures, implementing effective corrective and preventive actions.
Provide critical technical input for long-term strategic planning, including life-of-mine studies, resource evaluation, and corporate development opportunities.

Secondary Functions

Support cross-functional teams, including finance and supply chain, with ad-hoc technical analysis and data interpretation to inform business decisions.
Actively contribute to the site's overall continuous improvement and operational excellence programs (e.g., Six Sigma, Lean).
Collaborate with geology and mining departments to understand the upstream impact of ore variability and mine planning on downstream process performance.
Participate in site-wide safety audits, emergency response drills, and contribute actively to the development of a proactive safety culture.

Required Skills & Competencies

Hard Skills (Technical)

Process Chemistry: Deep understanding of aqueous chemistry, including leaching kinetics (e.g., pressure oxidation, cyanidation), precipitation, and crystallization.
Separations Technology: Expertise in solvent extraction (SX), ion exchange (IX), and membrane filtration for metal separation and purification.
Electrochemistry: Strong knowledge of electrowinning (EW) and electrorefining processes for final metal plating and purification.
Process Modeling & Simulation: Proficiency with industry-standard software such as METSIM, SysCAD, HSC Chemistry, or OLI Studio.
Mass & Energy Balancing: Ability to perform complex mass, water, and heat balances for entire circuits.
Metallurgical Accounting: Skill in developing and maintaining systems for tracking metal units and calculating recovery.
Process Control & Instrumentation: Ability to read and interpret P&IDs and understand the logic behind process control strategies.
Geometallurgy: Understanding the link between ore mineralogy, comminution, and hydrometallurgical response.
Data Analysis: Competency in using statistical tools, plant information (PI) systems, and data visualization to analyze process data.
Technical Writing: Ability to produce clear, concise, and defensible technical reports, procedures, and presentations.
Laboratory & Pilot Plant Operations: Hands-on experience with experimental design, operation of lab/pilot equipment, and scaling up results.

Soft Skills

Analytical Problem-Solving: A systematic and logical approach to diagnosing and resolving complex process issues.
Attention to Detail: Meticulous in observation, data collection, and analysis to ensure accuracy and safety.
Communication: Ability to clearly communicate complex technical concepts to a diverse audience, from plant operators to senior management.
Teamwork & Collaboration: A proven track record of working effectively within multidisciplinary teams (operations, maintenance, engineering).
Safety-First Mindset: An unwavering commitment to personal and process safety in all aspects of work.
Adaptability: Resilience and flexibility to work in challenging, fast-paced, and sometimes remote industrial environments.
Project Management: Ability to manage small to medium-sized projects, including defining scope, budget, and schedule.

Education & Experience

Educational Background

Minimum Education:

Bachelor's Degree (B.S. or B.Eng.) in a relevant engineering or scientific discipline.

Preferred Education:

Master's Degree (M.S.) or Doctorate (Ph.D.) focused on extractive metallurgy or a related field.

Relevant Fields of Study:

Metallurgical or Materials Engineering
Chemical Engineering
Mineral Processing Engineering

Experience Requirements

Typical Experience Range:

This is a role that scales with expertise. Entry-level positions may be available for new graduates, while typical roles require a minimum of 3-5 years of relevant experience in an operational, technical services, or R&D environment. Senior and Principal roles often require 10-15+ years of progressive experience.

Preferred:

Direct, hands-on experience in an operational role within a hydrometallurgical processing plant (e.g., copper SX-EW, gold CIL/CIP, nickel/cobalt HPAL, or lithium/battery recycling) is highly valued. A background that includes plant commissioning, process ramp-up, and leading continuous improvement projects is a significant asset.