Modelling Engineer R&D

JOB PURPOSE:

The Modeling Engineer within the CFD or FEM sub-team plays a critical role in new cell design development and design enhancement of existing cells by using advanced physics-based mathematical modelling solutions. The position is responsible for developing and applying advanced modeling techniques to the aluminum smelting process and its auxiliary systems.

This highly technical position involves a continuous learning journey, where the engineer builds expertise in cell design and industry-specific modeling approaches and deepens their understanding of the complex multiphysics phenomena involved in aluminum smelting. Starting by running and validating existing models, the engineer progressively takes on more responsibility, eventually contributing to the development of new designs, models and innovative solutions that enhance process efficiency.

Throughout their career, the engineer demonstrates a strong commitment to professional growth, improving both technical capabilities and communication and soft skills.

KEY ACCOUNTABILITIES:

• Technical Expertise in Multiphysics

  • Advanced Modeling Solutions:

    • Develop sophisticated models to accurately simulate complex multiphysics phenomena in the aluminum smelting process.

    • Ensure models are robust, accurate, and validated against empirical data.

    • Identify opportunities for modelling methods improvements and innovation.

  • Deep Cell Design and Process Understanding:

    • Develop cell design components by employing comprehensive models that reflect real-world conditions.

    • Identify opportunities for process improvements and innovation.

    • Provide expert reviews on initiatives from other teams and support the Process and Supply teams in the selection and approval of new lining and other key materials.

  • Tool Proficiency:

    • Expertly use available modeling tools and software specific to CFD or FEM.

    • Continuously improve modeling techniques and methodologies.

  • Quality Assurance – Model and Design Validation:

    • Oversee the validation of models through comparison with experimental data and operational results.

    • Lead preparation of the design validation program.

    • Adjust model parameters to ensure modeling outputs are accurate and reliable for decision-making purposes.

  • Documentation and Reporting:

    • Prepare detailed technical reports and documentation of modeling work.

    • Communicate findings effectively to stakeholders, including non-technical audiences.

• Technical Development

  • Learning and Training:

    • Engage in continuous learning to understand the cell design and modeling approaches used in the industry.

    • Participate in training programs to gain proficiency in cell design and modeling tools and techniques.

  • Process Understanding:

    • Develop a deep understanding of the aluminum smelting process, including its multiphysics complexities such as thermal dynamics, fluid flow, electromagnetism, and structural mechanics.

    • Expand knowledge from a single physics domain to multiple areas over time.

  • Process Improvement and Innovation:

    • Identify technical challenges and develop innovative solutions through modeling and simulation.

    • Collaborate with cross-functional teams to implement process enhancements.

  • Value Creation:

    • Use modeling approaches to develop/improve cell design and process performance, contributing to increased efficiency and effectiveness.

    • Analyze new methods and processes for aluminum production using modeling tools.

• Communication and Collaboration

  • Teamwork:

    • Collaborate effectively with team members, sharing knowledge and supporting collective goals.

    • Work cross-functionally with other departments such as Production and Engineering.

  • Communication:

    • Communicate modeling results and findings clearly to colleagues and supervisors.

    • Develop skills to present complex technical information to non-technical audiences.

AUTHORITY / DECISION MAKING:

• Technical Decisions:

  • Autonomy in selecting modeling approaches and setting parameters.

  • Autonomy in development of cell design components, subject to review by team leader.

  • Contribute to decision-making processes on technical matters.

• Project Responsibility – Mentoring and Training:

  • Manage assigned tasks effectively, ensuring timely and accurate completion.

  • Take ownership of work quality and reliability.

  • Lead small-scale modeling projects or specific aspects of larger projects.

QUALIFICATIONS & SKILLS:

• Education:

  • Bachelor’s or Master’s (preferred) degree in Engineering (Mechanical, Chemical, Metallurgical), Applied Mathematics, Physics, or a related field with a focus on modeling and simulation.

• Experience:

  • Five (5) years of relevant work experience as a modelling engineer.

  • Two (2) years of relevant work experience as a modelling engineer in an aluminium reduction related area.

  • Proven ability to handle complex modeling tasks independently.

• Technical Skills:

  • Modelling and Design Expertise:

    • Proficiency with modern modeling software:

      • For CFD Engineers: CFD tools such as ANSYS Fluent, OpenFOAM, or similar.

      • For FEM Engineers: FEM tools such as ANSYS Mechanical, COMSOL Multiphysics or similar.

    • Good general knowledge of different aspects of aluminium cell design. Should be an expert at least in two of the following areas:

      • Cell busbar design (thermo-electric and electromagnetic behaviors, MHD-stability).

      • Lining and potshell design (impact on heat balance or integrity).

      • Anode assembly design (impact on heat balance or integrity).

      • Superstructure design (fume capturing or mechanical integrity).

    • Solid knowledge of mathematics.

    • Good general knowledge of different areas of physics. Deep knowledge, understanding and engineering background in at least two of the following: heat and mass transfer, magnetohydrodynamic (MHD), electromagnetics, thermo-mechanics.

    • Preferably with a solid understanding of chemistry, combustion, electrochemistry.

    • Proficiency with the most modern modelling software available on the market and suitable for our business.

  • Process Knowledge:

    • Deep understanding of the aluminum smelting process and its multiphysics aspects.

    • Ability to model complex phenomena including thermal, fluid flow, structural, and electromagnetic interactions.

  • Validation and Analysis:

    • Deep knowledge of design and model validation process. Ability to create design validation programs.

    • Strong analytical skills to interpret modeling results and provide actionable insights.

    • Ability to analyse new methods and processes for production improvement.

    • Experience optimizing processes through data-driven modelling and simulation.

  • Analytical and Problem-Solving Skills:

    • Ability to analyse complex cause-and-effect relationships and patterns.

    • Proactive approach to identifying issues and seeking solutions.

    • Ability to work independently and make informed decisions.

    • Creativity in addressing technical challenges.

  • Leadership Skills:

    • Self-motivation.

    • Capacity for self-direction.

• Soft Skills:

  • Communication:

    • Good verbal and written communication skills in English.

    • Ability to document work clearly and present findings effectively.

  • Teamwork:

    • Collaborative mindset and ability to work within a team environment.

    • Respectful of diverse perspectives and open to feedback.

  • Continuous Learning:

    • Demonstrated enthusiasm for continuous learning and professional development.

    • Open to acquiring new skills and expanding knowledge areas.

  • Dedication:

    • Commitment to high-quality work and attention to detail.

    • Persistent in overcoming obstacles and achieving objectives.