KILN INCHARGE

Purpose/Objective

The Kiln Section Incharge oversees the efficient operation and management of the kiln section, ensuring the production of high-quality clinker in alignment with production targets. This role is responsible for optimizing kiln performance, managing energy consumption, and ensuring compliance with safety and environmental regulations. The Kiln Section Incharge also leads the kiln team, promoting a culture of continuous improvement and innovation.

Key Responsibilities of Role

Kiln Operations Management: Oversee the operation of kilns, including AFR co-processing, SNCR, and auxiliary equipment such as raw material transportation and dryers, ensuring optimal performance. Monitor kiln parameters continuously, making real-time adjustments to maintain stable operations and achieve production targets. Shift Coordination and Scheduling: Develop and manage shift schedules for CCR operators of the kiln, raw mill, and coal mill, ensuring seamless 24/7 operation and adequate shift coverage. Coordinate shift operations, ensuring clear communication and smooth handovers between shifts. Quality Control and Product Assurance: Ensure the production of high-quality clinker by closely monitoring kiln conditions and coordinating with the quality control laboratory to make necessary adjustments. Implement corrective actions promptly when deviations from quality standards are detected. Energy Efficiency and Resource Optimization: Maximize energy efficiency in kiln operations, implementing best practices to reduce energy consumption and optimize the use of alternative fuels. Regularly review and analyze energy consumption data, identifying opportunities for further efficiency improvements. Maintenance and Refractory Management: Plan and oversee the maintenance of kiln equipment, including regular inspections, repairs, and refractory installation during shutdowns. Ensure the selection and installation of high-quality refractory materials to prolong kiln life and maintain operational efficiency. Health, Safety, and Environmental Compliance: Ensure that all kiln operations comply with safety, health, and environmental regulations, promoting a culture of safety within the kiln team. Implement LOTOTO (Lockout/Tagout/Tryout) procedures during maintenance and equipment stoppages to prevent accidents and injuries. Internal Control and Fraud Prevention: Establish and enforce internal controls within the kiln section to prevent operational inefficiencies, financial leakages, and fraud. Maintain transparency in all kiln operations, ensuring accurate record-keeping and reporting of operational data. Team Leadership and Development: Lead, train, and develop the kiln operations team, providing guidance and support to ensure high performance and continuous improvement. Conduct regular performance evaluations and foster a collaborative work environment within the team. Commercial Responsibility: Monitor and control the operational costs associated with kiln operations, contributing to the overall profitability of the plant. Ensure that all kiln-related expenditures are documented and reported accurately, maintaining transparency in financial management. Innovation and Continuous Improvement: Stay updated on the latest developments in kiln technology and best practices, implementing innovative solutions to enhance kiln performance. Lead continuous improvement initiatives to optimize kiln operations and reduce operational costs. Key Stakeholders - Internal: Production Head Cement Mill Incharge Kiln CCR Operator Raw Mill Incharge Raw Material Incharge AFR Incharge Key Stakeholders - External: Refractory material suppliers Kiln maintenance contractors Environmental agencies

Technical Competencies

Chemical Process Integration-Cements,Contingency Planning-Cements,Data-Driven Decision Making-Cements,Energy Recovery Optimization-Cements,Material Science Expertise-Cements,Operational Excellence & Innovation-Cements,Pyro Process Optimization-Cements,Quality Assurance-Cements

Qualifications and Experience

Education Qualification: Bachelor’s degree in Mechanical or Chemical Engineering. Work Experience: 10+ years of experience in kiln operations within the cement manufacturing industry, with at least 3 years in a supervisory role. Industry Knowledge: Extensive knowledge of kiln operations, including AFR co-processing, SNCR, and auxiliary equipment. Proficient in energy efficiency practices, refractory management, and shift coordination.