Assistant General Manager GCP

Department:

Role Purpose:

Gas Cleaning Plant (GCP), Utility systems, and Stock House

Key Responsibilities:

1. Gas Cleaning Plant (GCP) Management

• Ensure smooth operation of GCP for effective cleaning of blast furnace gas.
  
• Monitor gas flow, pressure drop, dust load, and ensure clean gas supply to power plant and other units.
  
• Maintain high availability of GCP equipment (dust catcher, scrubbers, fans, pumps, and cooling towers).
  
• Drive energy optimization by reducing pressure drop and maximizing recovery of cleaned BF gas.
  
• Implement measures for zero gas leakage, reduced suspended dust, and compliance with emission norms.
  

2. Utility Systems Management

• Manage utilities for Blast Furnace such as compressed air, cooling water, nitrogen/oxygen supply, and hydraulic systems.
  
• Monitor utility consumption trends and implement energy efficiency measures.
  
• Ensure reliable supply of utilities to furnace, cast house, PCI, and GCP with minimal downtime.
  
• Plan preventive maintenance of pumps, compressors, cooling towers, and pipelines.
  
• Coordinate with central utility teams (oxygen plant, power plant, water treatment plant) for continuous supply.
  

3. Stock House Operations

• Ensure smooth, timely, and accurate charging of burden materials (sinter, coke, pellets, fluxes) to the furnace.
  
• Monitor stock house bin levels, weighing accuracy, charging sequence, and skip/ conveyor performance.
  
• Prevent raw material mix deviations and ensure proper burden distribution inside the furnace.
  
• Drive automation in stock house for accuracy, consistency, and reduced downtime.
  
• Coordinate with RMHS for raw material feeding and handling issues.
  

4. Maintenance & Reliability

• Develop preventive and predictive maintenance schedules for GCP, stock house, and utility systems.
  
• Lead shutdown planning and execution for annual/capital repairs.
  
• Analyze failures/breakdowns (RCFA) and implement corrective measures.
  
• Ensure optimum spare management and AMCs for critical equipment.
  

5. Safety, Environment & Compliance

• Ensure strict compliance with statutory regulations related to emissions, noise, water usage, and safety norms.
  
• Drive workplace safety culture in GCP, utility areas, and stock house.
  
• Implement ISO, TPM, and energy management standards.
  
• Ensure zero accidents in high-risk areas like stock house conveyors, high-pressure utilities, and GCP fans.
  

6. Production & Cost Optimization

• Support furnace operation by ensuring continuous raw material charging without delays.
  
• Optimize energy consumption in GCP and utility systems.
  
• Drive cost-saving initiatives in utility usage, gas cleaning, and spares consumption.
  
• Minimize GCP water and power consumption per ton of hot metal.
  

7. People Leadership & Training

• Lead a team of engineers, supervisors, and operators for round-the-clock operations.
  
• Build technical capability of the team on modern GCP and stock house automation systems.
  
• Motivate the workforce towards continuous improvement and zero breakdown culture.
  

Key Performance Indicators (KPIs):

• GCP:

  Availability (%), Dust load in cleaned BF gas (mg/Nm), Gas leakage incidents.

• Utilities:

  Energy consumption per THM, Cooling water losses, Air compressor efficiency.

• Stock House:

  Charging accuracy, Bin level deviations, Charging delays.
• Breakdown frequency & MTBF/MTTR.
  
• Safety performance (Zero LTI, near-miss reporting).
  
• Compliance with environmental emission norms.
  
• Cost per THM (supporting furnace operation).
  

Qualification & Experience:

• B.E./B.Tech in Mechanical / Electrical / Metallurgy / Chemical Engineering.
  
• 15–20 years of experience in Blast Furnace auxiliary operations (GCP, utilities, and stock house).
  
• Strong knowledge of gas cleaning, stock house automation, utility systems, and preventive maintenance.
  
• Experience in managing shutdowns, capital repairs, and compliance audits.
  

Skills & Competencies:

• In-depth technical knowledge of GCP, utilities, and stock house equipment.
  
• Leadership skills to manage cross-functional teams.
  
• Analytical & problem-solving ability for breakdowns and process deviations.
  
• Knowledge of ERP/SAP for production, inventory, and maintenance planning.
  
• Strong communication and coordination skills with Furnace, RMHS, Utility, and Power Plant teams.
  
• Safety-first mindset with knowledge of statutory & environmental standards.