Officer/Senior Officer -Process (Kiln & Coal Mill Operation), Basantnagar Cement Works, Telangana Full Time

This position is for Basantnagar Cement Works, Telangana

PF Process (Kiln & Coal Mill Operation)

Officer/Senior Officer/ Assistant Manager

JB 11

Job Purpose:

To operate and optimize the kiln system, coal mill, and associated equipment to achieve high productivity, stable operation, fuel efficiency, and quality clinker within safety and environmental compliance norms.

Supervise & monitor to ensure running of Kiln operations without any trouble at optimized cost with defined parameter for uninterrupted plant production and quality.

Key Performance Indicators (KPIs):

• Kiln feed rate & clinker production.
• Kiln thermal energy consumption (kcal/kg clinker).
• Coal mill output & specific power consumption.
• Clinker quality parameters (LSF, C3S, free lime).
• Kiln & coal mill availability.
• Safety compliance & zero breakdown due to operational error.

KRA-1: Operational management (Operation of Kiln & Coal) to achieve the targeted production and quality).

• Monitor kiln parameters (SF, LSF, BZT, RPM, draft, kiln load) through CCR.
• Perform smooth kiln start-up, shutdown, and emergency handling.
• Maintain stable burning zone temperature, clinker quality, and heat consumption.
• Optimize kiln speed, cooler fans, and burner settings.
• Coordinate with field operators for inspection and feedback.
• Control ring formation, snowman, red river, and other operational issues.
• Start, stop, and operate the ball coal mill from CCR.
• Maintain target fineness and residue as per kiln requirement.
• Ensure stable mill outlet temperature, differential pressure, and feed rate.
• Coordinate with maintenance team for breakdown and lubrication issues.

KRA-2: Cost Control

• Sp. Power consumption To avoid Idle running of the circuit,
• Optimizing operation by reduction in RPM cost along with Reduction in Stores & spares cost
• Delivery Specific Heat Reduction and Reduction in Specific Heat consumption
• Reducing breakdown by early detection of abnormalities
• Timely completion of kiln shut down activity.

KRA-3: Continuous improvement

• Increasing output rate
• Reduction in breakdown, Process trend analysis, Field visit and observation, Reducing abnormalities.
• Compliance to SAP PM module for shutdown activities, orders booking and history updation Improvement in productivity of Kiln by optimising the operations and consistency.
• Improvement in productivity of Kiln by optimizing the operations and consistency.

KRA-4: Safety, Health & Environment along with Sustainability initiatives

• Ensuring 100% compliance of all safety standards and all applicable recommendations related to their concerned area.
• Educating team about “I know my job”, “I know the hazards associated with my job and I applied control measures” & “I escalate to my senior” among manpower deployed in sections/department manpower including peer, WB & CL manpower
• Timely conducting scheduled SO round and reporting of accidents, incidents and near misses on occurrences in the area of concern in system.
• To conduct daily Tool Box Talk as schedule and before start the job any critical job along with SWP
• Active participation in safety training, safety sub committees, standard champions meeting and any safety event
• Ensure good housekeeping, limited use of power, no leakage of water, oil, air etc and reporting concerned if any abnormalities for corrective action
• Adhering of all safety precautions on the site and off the site.
• Replicating good practice for saving environment for long run sustainability and creating awareness among manpower to save guard natural resources.

KRA-5 – System Management

• Prepare shift reports on kiln operation, coal mill performance, and downtime.
• Log all parameter changes and process deviations.
• Communicate abnormalities to the shift in?charge and maintenance teams.