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
- 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 incharge and maintenance teams.
