CCR operator-Refractory management

Purpose/Objective

Operate the kiln–preheater–calciner–cooler through the CCR (DCS/SCADA) to ensure stable burning zone, optimal clinker quality, and refractory protection. Monitor temperatures, drafts, and process profiles; respond to upsets; coordinate with field teams for inspections and cleaning; and enforce heatup/shutdown protocols to maximize refractory life and minimize thermal/mechanical shocks.

Key Responsibilities of Role

Control Room Operations (Refractory Focus)- Run kiln/calciner/cooler with strict adherence to heat-up/soak/shut-down curves to prevent refractory damage. - Maintain burning zone temperature (BZT), sintering zone profile, and preheater/calciner temperature & P within limits. - Control drafts/pressures (kiln inlet, preheater riser, tertiary air) to avoid hot spots and false air stress on refractory. B) Monitoring & Upset Management- Track shell temperatures (scanner/pyrometer), identify hot spots, and initiate corrective actions (feed, speed, flame shape, air/fuel balance). - Detect and respond to ring formation, snowman/red river, cyclone buildups, ensuring safe cleaning plans with Maintenance/Production. - Limit CO excursions and rapid temperature swings that risk spalling. C) Coordination with Field & Maintenance- Raise work orders for suspected refractory distress (coating loss, persistent hot spot, seal leakage). - Coordinate inspections during stops; support mechanical adjustments (seals, thrust control) that influence refractory stress. - Participate in refractory relining/patching windows: pre/post checks, heatup regime, and controlled rampup. D) Quality & Data Integrity- Ensure clinker chemistry (LSF/SM/AM) and free lime are within targets via stable burning; log deviations and actions. - Maintain high-quality shift logs (events, setpoints, corrective actions); use historian trends for RCA. E) EHS & Permit Discipline- Enforce PTW/LOTO and confined space protocols for any cleaning/inspection; follow emergency purge procedures. - Conduct toolbox talks with field teams before refractoryrelated interventions

Technical Competencies

Kiln Operation & Stability,Refractory Awareness,Preheater/Calciner Control,Combustion & Emissions

Qualifications and Experience

- Education: Diploma/BE in Chemical/Ceramics/Mechanical (process exposure preferred). - Experience: 3–7+ years in CCR kiln operations with demonstrated refractory protection and upset handling. - Preferred Exposure: Rotary kiln with multistage preheater/calciner, grate cooler, AFR coprocessing basics, DCS platforms (ABB/Siemens/Honeywell/Rockwell).