Head of Smelter

• Department/Unit: Smelter Operations Reporting To: Head of Operations & Maintenance (O&M) Direct Reports: Smelter Shift In-charges, Smelter Process Engineer (if separate from central process engineering)

Job Purpose/Summary:

• To lead and manage all operational aspects of the Smelter unit, ensuring safe, efficient, and compliant production of anode copper. This role is responsible for optimizing smelting processes, achieving production targets, and maintaining high product quality.

Key Responsibilities & Duties:

• Operational Management: Oversee daily smelting operations, including furnace charging, tapping, converting, and anode casting, to meet production schedules and quality specifications.
• Process Optimization: Continuously monitor and analyze smelting process parameters to identify opportunities for efficiency improvements, energy reduction, and increased metal recovery. Production Planning: Work with O&M Head to develop and implement daily, weekly, and monthly production plans for the smelter.
• Safety & Environment: Ensure strict adherence to all safety protocols, environmental regulations (e.g., emissions control), and waste management procedures within the smelter.
• Quality Control: Collaborate with the Quality Control department to ensure anode copper meets required specifications and resolve any quality deviations.
• Resource Management: Optimize consumption of raw materials, fluxes, and utilities. Manage manpower and equipment effectively within the smelter. Troubleshooting: Lead the identification and resolution of complex operational issues, equipment malfunctions, and process upsets.
• Team Leadership: Lead, mentor, and develop Smelter Shift In-charges and other operational staff. Foster a culture of continuous improvement and operational discipline.
• Maintenance Coordination: Liaise closely with the Maintenance team for planning and execution of smelter equipment maintenance, shutdowns, and overhauls. Reporting: Prepare comprehensive operational reports, analyze performance data, and present findings and recommendations to the O&M Head.

Key Performance Indicators (KPIs):

• Anode Copper Production Volume (Tons/Month)
• Copper Recovery in Smelter (%)
• Smelter Process Efficiency
• Energy Consumption per Ton of Anode Copper
• Smelter Downtime (Planned vs. Unplanned)
• Product Quality (Anode Purity, Weight Consistency)
• Safety Incidents in Smelter
• Compliance with Emission Standards

Required Qualifications:

• Bachelor's degree in Metallurgical Engineering.

Required Experience:

• 15+ years of experience in copper smelting operations, with at least 5-7 years in a leadership/managerial role within a smelter.
• Extensive knowledge of various smelting technologies (e.g., Flash Smelting, ISASMELT, Pierce-Smith Converters, Anode Casting).

Required Skills:

• In-depth knowledge of pyrometallurgy and smelting process control.
• Strong leadership, analytical, and problem-solving skills.
• Excellent decision-making abilities, especially under pressure.
• Proficiency in process optimization techniques.
• Solid understanding of industrial safety and environmental regulations.
• Effective communication and interpersonal skills.