Preheat oven to 350 degrees F.

Spread almonds in a single layer on a rimmed baking sheet.

Roast almonds for 15 minutes, then remove from oven and transfer to a large bowl to cool completely.

Place butter on rimmed baking sheet; return to oven until butter is melted, about 5-7 minutes.

Remove from oven and set aside.

In a large bowl or bowl of a stand mixer, whisk egg whites and 1/2 teaspoon salt on medium speed until egg whites are frothy.

Gradually add sugar.

Increase speed to medium high and whisk until egg whites begin to form stiff peaks.

Add remaining 1/2 teaspoon salt, cocoa powder and chili powder and whisk until well combined.

Pour egg white mixture over cooled almonds and stir to combine.

Spread almond mixture in a single layer over melted butter on baking sheet.

Return to oven and bake 30-40 minutes, stirring almonds every 10 minutes, until done.

Remove from oven and let cool completely.

Almonds will stay fresh in an airtight container at room temperature for up to 1 week.