1) Job Purpose:Write the purpose for which the job exists (in 2-3 lines)

To analyze and monitor process control (Know-how) and quality parameter for Smelters-1 and Smelter-3, which includes different technologies, various furnaces, Waste heat recovery boilers, ESPs, Environment related systems to meet business objectives.

Monitoring furnace campaign life and drive process improvements to reduce losses and waste.

Update operational/process SOPs and train staff for improvement in process control practices.

Analyze raw material quality and explore cost-effective alternatives to fulfil business requirements. Benchmark process and quality, introduce new technologies, and promote sustainability.

Ensure the efficient operations and production cost reduction of both the Smelters as per world class norms. Collaborate on digital transformation efforts for both Smelters-1 and Smelter-3.

Collaborate with PBU Heads, AET- team, DMT - teams for quality improvement and smooth operations.

2) Dimensions:Mention quantitative or qualitative parameters that are relevant for the job and provide a better understanding of the scope and scale of the job.

Business Workforce Number

MG 368, LMS 69. OG 1042, Contract workmen - 2881

Unit Workforce Number

Staff (Management & LMS)- 437

Workmen- 1042, Contract Workmen- 2881

(Unit and business workforce no are same - To be corrected)

Function Workforce Number

90 (MG - 18Nos, LMS - 39Nos. & OG - 8Nos.) + 25 Contract

Department Workforce Number

Other Quantitative and Important Parameters for the job: Budgets/ Volumes/No. of Products/Geography/ Markets/ Customers or any other parameter

Copper Anode Production- 439000 T

Acid Production- 1150000T

Data analysis projects.

Job Context:

Birla Copper has a copper smelting and refining complex at Dahej, producing copper cathodes, cast copper rods, precious metals such as gold, silver and selenium, and other by-products such as Sulphuric acid, etc., in multiple plants with different technologies requiring diverse competencies. Recognized globally for quality, it holds ISO 9001, 14001, 27001, 50001 and OHSAS 18001 certifications and is registered on the London Metal Exchange as a Grade-A copper brand. Birla Copper plant has two copper smelters operating using two different technologies: smelter-1(Outotec) and smelter-3 (Mitsubishi). These smelters process blended copper concentrates of varying specifications and supply copper as anodes of 99.5% purity to the attached refineries to make copper cathode.

The challenges and complexity of copper pyrometallurgy operations intensify the need for process analysis to improve operational control, plant productivity, and furnace campaign life. The know-how of the process is very important for Identifying key improvement areas and developing strategies to overcome the challenges necessary for sustainability and consistent product quality. In addition, it is increasingly crucial to integrate digital solutions to optimize operations, implement condition-based monitoring, and predict equipment failures.

In this regard, this role is responsible for the following:

Conduct technical analysis and process control for efficient copper smelting, converting and anode caster operations. Understanding Mitsubishi and Flash Smelting technologies to address unique challenges. Optimize blend ratios and manage furnaces to ensure coordinated operations and improved efficiency. Implement technological enhancements for reliable smelting, focusing on extending furnace campaign life. Promote digital transformation for better automation and data analytics, using digital tools to optimize processes by reducing human interventions. Ensure high-quality copper anode production and maintain strong internal customer relationships. Lead interplant visits for best practice sharing and host foreign delegates to showcase plant operations.

Understand and optimize various plant processes, including boiler operations, ESP, environmental equipments like bag house & scrubber systems. Collaborate with external agencies and research institutes to resolve technical issues and enhance efficiency.

Monitor work-in-progress (WIP) materials for optimal cash flow and inventory management. Track consumption to meet production and budget targets, analyzing data and implementing corrective actions as needed.

Key Challenges:

• Managing diverse smelter technologies - Mitsubishi (No OEM Support) and Flash Smelting, one of its kind in India.
• .Monitoring and controlling diverse technologies for smelter operations, including a one-of-a-kind Japanese technology (Mitsubishi) that requires extremely skilled individuals to monitor complex and highly sensitive operations and ensure timely upgrades
• It involves optimizing blend (average blend runs for 4-5 days and it takes 1-2 days to stabilize operation) by using various types of concentrates to ensure consistent/homogeneous quality, as concentrate procured of different quality and huge variation in copper grades which deteriorates over period and increased impurities, making it challenging to operate the furnace and coordinating furnace operations to prevent bottlenecks. Operational people face challenges, implementing technological enhancements for reliability, longevity, and driving digital transformation as both smelters work on different technologies having a unique issue.
• Frequent boiler and throat jamming in SM-1 needs explosive blasting in the boiler for cleaning jamming of sintered concentrate with impurities.
• Monitoring WIP (Dust & Lumpy of SM-3 and Revert of SM-1-Blocked Copper inventory) generation and consumption as there are different areas and times it gets generated in both the smelters and need more focus for its liquidation due to operational issues.
• Hosting delegates fosters collaboration and obtaining operations and technical information. Challenges arising from unique and non-recurring process issues.
• To integrate the latest best practices for stringent environmental and safety compliance while balancing crucial operational and strategic goals.
• Managing stakeholder expectations is challenging, as our team does not have direct control over the operation's resources.
• Continuous skill development and addressing data quality issues are challenging for reliable analysis. Overcoming traditional methods and mindsets to improve teamwork and collaboration. Understanding the right refractory materials for different types of furnaces is vital.
• It is essential to regularly assess and upgrade the outdated equipment in the existing system.
• .To improve automation and data analytics, as the generation and gathering of quality data remains an issue.
• . Environmental Challenges: The coastal location and handling of high-sulphur gases result in increased corrosion and structural weaknesses, requiring continuous upkeep.

• . Ensuring operation/process control of the Smelters with the envisaged wide variation in quality of concentrate for achieving the desired volume with LME grade quality and better efficiency to fulfil business requirements.

4) Key Result Areas:Writethe key results expected from the job and the supporting actions for each of these key result areas (For a majority of jobs typically there could be 4- 7 key result areas)

Operational Excellence and Process Control

• Perform heat and mass balance for the copper smelting and converting process and assist in optimum blend preparation and feed input for the furnace.
• Improve operational efficiencies to reduce specific consumption and cost of production.
• Timely upgradation of Process SOPs.
• Conduct regular and detailed technical analysis of both Mitsubishi and Flash Smelting & Converting processes.
• Implement advanced process control systems to monitor and adjust operations for optimal performance.
• Develop and maintain comprehensive documentation of process parameters and performance metrics.
• Smooth and efficient operations to enhance furnace campaign life.

Customer-centricity

• Achieving internal customer satisfaction through improving internal responses.
• Ensure the production of high-quality copper anodes that meet or exceed industry standards.
• Address any quality issues promptly to maintain product quality.
• Maintain strong relationships with internal customers by addressing their needs and ensuring consistent product quality.

Sustainability and Process Improvement

• Giving inputs for plant improvement and sustainability through best practice benchmarking, leveraging team suggestions and executing changes

• Kaizen Implementation.
• Emphasize waste reduction and decreasing the carbon footprint.
• Implement pilot projects to test the effectiveness of new technologies before full-scale adoption.
• Regularly review and adopt best practices in copper manufacturing to drive operational excellence.

Budgetary Controls

• Identify areas and solutions to increase WIP liquidation -by reducing generation and increasing consumption.
• Monitoring and help in reduction of specific consumption to reduce cost of production.

• Flag the issues to relevant teams for timely actions and avoid unplanned breakdowns.

People development and engagement

• Sharing of knowledge and learning with members for self and team development.
• Collaborate with external agencies and research institutes to resolve technical bottlenecks and develop new technologies.
• Engage in industry forums and workshops to stay updated on technological advancements.
• Develop and maintain strong partnerships with external organizations to drive continuous improvement.
• Maintain open communication channels with external partners to ensure timely and effective solutions.

Cultural change towards Digitalization

• Introducing new ways of doing daily tasks with available automation techniques/software.
• Spread awareness about digitalization among operators and managers.

• Participation in workshops/trainings.
• Address the challenge of conventional working and thinking methodologies among plant personnel.
• Promote a culture of continuous improvement and innovation to drive process advancements.
• Provide training and development programs to encourage innovative thinking and problem-solving skills.