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Electrolysis Engineer
Location: Ellesmere Port, Cheshire
Salary: Competitive, dependent on experience
Contract: Permanent, full-time
The Opportunity
Are you an experienced Electrolysis Engineer, Metallurgical Engineer or Aluminium Process Specialist with a strong background in industrial molten-salt electrolysis?
Are you interested in applying your technical expertise to the development of advanced rare-earth metal production processes?
We are recruiting on behalf of our client, a specialist metals manufacturing business, for an experienced Molten Salt Electrolysis Specialist to join its Research & Development function at its Ellesmere Port facility.
This is a highly technical opportunity focused on developing, optimising and scaling up industrial electrochemical processes for the production of rare-earth metals and alloys, including neodymium (Nd), neodymium-praseodymium (NdPr) and DyFe.
Drawing on your experience of industrial aluminium electrolysis, high-temperature electrochemistry and fluoride-based molten-salt systems, you will help develop and improve electrolysis technologies, taking processes from technical development through to reliable industrial production.
You will work across R&D, metallurgy, engineering and production, helping to improve cell performance, metal quality, production efficiency and overall process reliability.
The Role
Reporting to the Director of Research & Development, you will provide specialist technical expertise in molten-salt electrolysis, supporting the development, optimisation and industrialisation of rare-earth metal production processes.
Key responsibilities will include:
- Developing, optimising and scaling up molten-salt electrolysis processes for rare-earth metals and alloys, including Nd, NdPr and DyFe.
- Establishing and optimising critical electrolysis operating parameters, including electrolyte composition, oxide concentration, impurities and operating temperatures.
- Investigating electrolyte chemistry and developing strategies to maintain stable operating conditions through controlled feeding and bath management.
- Identifying and minimising sources of contamination to improve final metal quality and product consistency.
- Analysing process data to understand relationships between operating conditions, current efficiency, energy consumption and metal quality.
- Leading structured experimental programmes, industrial plant trials and technical investigations to improve electrolysis performance.
- Supporting the development and improvement of electrolysis cell design, electrode systems, feeding arrangements, process controls and instrumentation.
- Identifying opportunities to increase production capacity, cell productivity, reliability and operating life.
- Supporting the transition of new electrolysis technologies from laboratory and pilot-scale development through to industrial production.
- Working collaboratively with Materials & Characterisation, Chemical Engineering, Technical Engineering, Production, Maintenance and HSE teams.
- Developing operating procedures, technical specifications, process-control strategies and technical reports.
- Supporting equipment suppliers and engineering partners with the design, development and commissioning of new or upgraded electrolysis systems.
About You
You will be an experienced electrolysis or metallurgical engineering professional with a strong technical understanding of industrial molten-salt electrochemical processes.
Ideally, you will have direct experience within aluminium electrolysis or primary aluminium production, with hands-on involvement in operating, developing or troubleshooting industrial electrolysis cells.
You will be comfortable working across technical development and industrial operations, using process data, structured investigations and engineering knowledge to improve cell performance and production efficiency.
Essential experience and qualifications:
- Degree in Metallurgy, Materials Science, Chemical Engineering, Electrochemistry, Process Engineering or a closely related discipline.
- Industrial experience within aluminium electrolysis or primary aluminium production.
- Hands-on experience operating, developing or troubleshooting industrial molten-salt electrolysis cells.
- Strong understanding of high-temperature electrochemistry and fluoride-based molten-salt systems.
- Experience investigating and improving electrolyte chemistry, cell stability and operating performance.
- Understanding of current efficiency, energy consumption and electrolysis process optimisation.
- Strong analytical, technical problem-solving and root-cause investigation skills.
- Experience working across R&D, engineering and industrial production environments.
Desirable experience:
- Previous experience in rare-earth metallurgy or rare-earth molten-salt electrolysis.
- Experience with neodymium (Nd), NdPr or other rare-earth metal production.
- Experience with process scale-up, industrial R&D and equipment commissioning.
- Knowledge of analytical techniques used to characterise electrolytes, feedstock materials and final metal quality.
- Experience developing new electrochemical processes or improving existing industrial production technologies.
Why Consider This Opportunity?
- Join a specialist metals manufacturing business investing in advanced production technologies.
- Work on specialist rare-earth metal and alloy production processes.
- Apply your industrial electrolysis knowledge to a technically challenging area of metallurgy.
- Take an active role in R&D, process development and industrial scale-up.
- Work alongside multidisciplinary technical, engineering and production teams.
- Influence improvements in production efficiency, metal quality and electrolysis technology.
If you are an experienced Aluminium Electrolysis Engineer, Metallurgical Engineer or Electrochemical Process Specialist looking for an opportunity to apply your expertise to advanced materials manufacturing, we would welcome your application.
Your CV will be forwarded to Jonathan Lee Recruitment, a leading engineering and manufacturing recruitment consultancy established in 1978. The services advertised by Jonathan Lee Recruitment are those of an Employment Agency.
In order for your CV to be processed effectively, please ensure your name, email address, phone number and location (post code OR town OR county, as a minimum) are included.
7220050 – Lee Elwell