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

Job Description

Job Purpose

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

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

KRA-3:Continuous improvement

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

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

1.Ensuring 100% compliance of all safety standards and all applicable recommendations related to their concerned area.
2.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
3.Timely conducting scheduled SO round and reporting of accidents, incidents and near misses on occurrences in the area of concern in system.
4.To conduct daily Tool Box Talk as schedule and before start the job any critical job along with SWP
5.Active participation in safety training, safety sub committees, standard champions meeting and any safety event
6.Ensure good housekeeping, limited use of power, no leakage of water, oil, air etc and reporting concerned if any abnormalities for corrective action
7.Adhering of all safety precautions on the site and off the site.
8.Replicating good practice for saving environment for long run sustainability and creating awareness among manpower to save guard natural resources.