Project Manager - Smelting & Refining at HAILIANG COPPER TEXAS INC – Sealy, Texas

POSITION SUMMARY

The Project Manager – Copper Smelting & Refining Facilities is responsible for the end-to-end planning, coordination, and execution of projects involving the construction, installation, and commissioning of industrial furnaces and associated systems used to melt scrap copper, remove impurities, and produce high-purity copper cathode for downstream manufacturing of pipes, tubes, and fittings.

This role provides full lifecycle project management oversight, ensuring that engineering, construction, commissioning, and start-up activities are completed safely, on schedule, within budget, and in full compliance with environmental, safety, quality, and metallurgical performance requirements.

KEY RESPONSIBILITIES

Project Planning & Execution

• Lead all phases of furnace construction and refining system projects, from concept and detailed design through installation, commissioning, and handover to operations.
• Implement company construction policies, project management standards, and execution plans to achieve project scope, schedule, cost, and performance objectives.
• Develop and manage detailed project execution plans, including schedule control, cost control, risk management, and resource planning.
• Coordinate and supervise on-site construction activities to ensure safe, efficient, and compliant project execution.

Process & Technical Oversight

• Review and verify process flow diagrams (PFDs), piping and instrumentation diagrams (P&IDs), furnace designs, electrical and automation systems, and construction drawings.
• Ensure furnace systems meet metallurgical performance requirements for melting scrap copper, impurity removal, and production of near-pure copper cathode.
• Participate in design reviews and technical workshops to identify risks, inefficiencies, or design gaps and propose optimized solutions.
• Review and approve technical submittals, equipment specifications, refractory systems, burner systems, off-gas treatment systems, and material handling designs.

Construction & Contractor Management

• Coordinate and manage EPC contractors, construction firms, supervision companies, equipment suppliers, and vendors to ensure compliance with contract requirements.
• Ensure all construction activities comply with approved drawings, specifications, and quality standards.
• Review and approve construction progress, milestone completion, and payment applications in accordance with contract terms.
• Strictly control engineering changes, field modifications, rework, and extra-scope activities to manage cost and schedule impact.

Safety, Environmental & Regulatory Compliance

• Ensure compliance with all applicable environmental, occupational safety, fire protection, and industrial hygiene regulations.
• Oversee implementation of safe work practices related to high-temperature operations, molten metal handling, refractory installation, and confined space work.
• Coordinate environmental permitting, emissions controls, and waste handling requirements related to copper melting and refining processes.
• Promote safe and compliant construction practices throughout all phases of the project.

Commissioning & Start-Up

• Lead furnace cold commissioning, hot commissioning, trial runs, and ramp-up activities.
• Coordinate process testing, metallurgical validation, and performance acceptance to confirm copper purity and production targets.
• Support training of operations and maintenance personnel prior to handover.
• Manage final acceptance, documentation, and transition of the facility to production operations.

Project Close-Out & Handover

• Ensure completion of all inspections, punch-list items, and regulatory filings.
• Collect and submit all project documentation, as-built drawings, test reports, and operating manuals.
• Participate in final project acceptance and post-project evaluations.

Required Knowledge & Competencies

• Strong understanding of industrial copper smelting, refining, and cathode production processes.
• Familiarity with scrap copper melting, impurity removal techniques, and metallurgical quality control.
• Ability to interpret and coordinate complex engineering drawings, process documentation, and construction plans.
• Strong coordination skills across engineering, construction, automation, environmental, and operations teams.

QUALIFICATIONS

Education

• Bachelor’s degree or higher in Metallurgical Engineering, Materials Engineering, Chemical Engineering, Mechanical Engineering, or a related technical discipline.

Experience

• Minimum of 5 years of experience in industrial furnace, smelting, refining, or metallurgical project management.
• Demonstrated experience managing the construction and commissioning of industrial furnaces or high-temperature process equipment.
• Experience with copper, aluminum, steel, or non-ferrous metal processing facilities is strongly preferred.
• Familiarity with cathode production, refining, or downstream copper manufacturing processes is a plus.

Certifications (Preferred)

• Professional Engineer (PE), Project Management Professional (PMP), or equivalent technical/project certification.
• Experience working within EPC or owner-operator project environments.

Skills & Abilities

• Strong project planning, organization, and execution capabilities in complex industrial environments.
• Excellent problem-solving, judgment, and decision-making skills.
• Strong communication and leadership skills with cross-functional teams and contractors.
• High attention to safety, quality, and operational reliability.
• Ability to manage multiple stakeholders and work effectively under pressure.
• English & Chinese bilingual preferred but not required