KILN INCHARGE

Purpose/Objective

The Kiln CCR Operator is responsible for the continuous monitoring and control of kiln operations from the Central Control Room (CCR), ensuring optimal performance and the production of quality clinker. This role involves real-time adjustment of kiln parameters, troubleshooting operational issues, and maintaining accurate operational data records. The Kiln CCR Operator plays a critical role in ensuring the efficient and safe operation of the kiln during assigned shifts.

Key Responsibilities of Role

Process Monitoring and Control: Continuously monitor kiln parameters, including temperature, pressure, and material feed rates, through the Central Control Room, making real-time adjustments to ensure optimal kiln performance. Operate auxiliary equipment, such as AFR co-processing units and SNCR systems, to maintain energy efficiency and production targets. Shift Operations Management: Collaborate with the Kiln Section Incharge to ensure smooth operations during assigned shifts, maintaining clear communication with other CCR operators and shift teams. Log operational data accurately and promptly, ensuring that all shift activities are documented for transparency and future analysis. Troubleshooting and Problem-Solving: Identify and respond to operational issues promptly, coordinating with maintenance and quality teams to address problems and minimize downtime. Implement corrective actions to resolve process deviations and ensure continuous production. Quality Assurance: Ensure that clinker produced during the shift meets the required quality specifications, coordinating with the quality control lab to verify product standards. Adjust kiln operations as needed to maintain product quality and consistency. Health, Safety, and Environmental Compliance: Adhere to all safety protocols and environmental regulations, ensuring that kiln operations are conducted in compliance with company policies. Implement LOTOTO procedures during equipment stoppages and maintenance activities to prevent accidents and ensure safe working conditions. Internal Control and Transparency: Maintain transparency in all CCR operations, ensuring that operational data is accurately recorded and reported to the Kiln Section Incharge. Implement internal controls to prevent fraud, operational inefficiencies, and data manipulation. Energy Efficiency and Resource Management: Optimize the use of energy and raw materials during kiln operations, implementing best practices to reduce consumption and enhance efficiency. Monitor energy usage continuously and report any deviations or opportunities for improvement. Continuous Learning and Improvement: Participate in training and development programs to enhance technical skills and operational knowledge, staying updated on the latest kiln technologies and best practices. Identify opportunities for process improvements and suggest innovative solutions to enhance kiln performance. Commercial Responsibility: Contribute to cost-effective kiln operations by optimizing process efficiency and minimizing waste, ensuring that operational costs are kept within budget. Ensure accurate documentation and reporting of all kiln-related activities during shifts. Ethics and Integrity: Uphold the highest standards of ethical behavior in all CCR operations, ensuring compliance with company policies and regulations. Report any unethical practices, discrepancies, or safety violations to the Kiln Section Incharge immediately. Key Stakeholders - Internal: Cement Mill Operator Kiln Section Incharge Raw Mill Incharge Key Stakeholders - External: Maintenance contractors

Technical Competencies

Contingency Planning-Cements,Data Analysis and Reporting-Cements,Energy Recovery Optimization-Cements,Material Science Expertise-Cements,Operational Excellence & Innovation-Cements,Process Control Systems-Cements,Quality Assurance-Cements

Qualifications and Experience

Education Qualification: Diploma or Bachelor’s degree in Mechanical, Chemical, or Electrical Engineering. Work Experience: 5+ years of experience as a CCR operator, specifically in kiln operations within the cement industry. Industry Knowledge: In-depth knowledge of process monitoring, real-time kiln parameter adjustments, and troubleshooting. Familiarity with auxiliary equipment, quality assurance protocols, energy management, and SHE compliance. Strong focus on operational transparency, data accuracy, and continuous improvement in kiln operations.