Operations Head

Gateway Green Resources is a Chennai-based tyre recycling company specialising in the shredding and pyrolysis of waste and scrap tyres using an advanced continuous process plant.

Our process recovers high-value outputs such as steel scrap, charred carbon black, and tyre pyrolysis oil, thereby supporting a more circular and sustainable materials economy.

Located in SIPCOT, Gummidipoondi, Chennai, our facility is built for high-efficiency, continuous processing of End-of-Life Tyres (ELTs).

Department: Pyrolysis Operations

Location: Gummidipoondi, Chennai

Team Reporting: Pyrolysis Operators, Maintenance Technicians (shared), Production & Quality In-Charge (functional), Helper Staff

Role Objective:

To ensure efficient, continuous, and environmentally compliant operations of the tyre pyrolysis plant — focusing on oil yield, carbon quality, machine uptime, and coordination across four pyrolysis units.

Qualification:

• Essential: B.E. / B.Tech in Chemical, Mechanical, Petrochemical, or Environmental Engineering

• Preferred: Training in hazardous operations, DCS systems, or CPCB/TNPCB compliance

Experience:

• 5+ years of plant operations experience in chemical processing, pyrolysis, or refinery/oil recovery plants

• Hands-on experience managing continuous pyrolysis machines or continues operations in other industries and shift operations

Key Responsibilities:

1. Production & Process Control

• Manage daily operations of all pyrolysis units in coordination with shift operators

• Monitor reactor parameters: temperature, pressure, feed rate, residence time, gas recovery

• Ensure consistent oil and carbon output with minimal deviation from yield targets

2. Manpower & Shift Oversight

• Plan operator and helper schedules to cover 24/7 continuous operation

• Supervise start-up, running, and shutdown activities across all machines

• Conduct daily debriefs with operators and guide them on SOP adherence

3. Machine & Utility Coordination

• Ensure availability and health of burners, condensers, oil tanks, scrubbers, and heat exchangers

• Collaborate with Maintenance Technicians for scheduled and emergency maintenance

• Oversee gas combustion or reuse processes (if applicable)

4. Safety & Environmental Compliance

• Enforce EHS protocols (PPE, fire control systems, hot work permits)

• Maintain records required by TNPCB/CPCB: stack emissions, effluent logs, waste manifests

• Monitor gas leaks, flare systems, and reactor seals to prevent incidents

5. Product Quality Assurance

• Work with Production & Quality In-Charge to ensure TPO flash point, viscosity, and carbon fineness are within acceptable limits

• Implement process changes based on lab results or customer feedback

• Maintain traceability of production batches

6. Inventory & Material Coordination

• Coordinate with shredding unit for feedstock flow (steel-free chips)

• Manage storage of TPO and carbon, ensure timely transfer to dispatch

• Ensure accurate tank measurement, weighing, and loading logs

7. Reporting & Documentation

• Submit daily production and machine logs to Operations Head

• Maintain maintenance history, operator attendance, and safety audits

• Record TPO & carbon yield vs. input ratio per batch or per shift

8. Continuous Improvement

• Identify opportunities for improving yield, reducing downtime, and saving energy

• Suggest automation or process control upgrades (e.g., sensor integration, SCADA)

• Implement Kaizen or root cause analysis for chronic issues

Key Performance Indicators (KPIs):

·      TPO Yield %

·      Carbon Yield %

·      Machine Uptime

·      Safety Incident Count

·      Unplanned Downtime

·      Environmental Compliance

Skills & Competencies:

• In-depth understanding of pyrolysis reaction dynamics and thermal control

• Ability to interpret DCS/SCADA or PLC system trends

• Crisis management and emergency response skills

• Strong reporting and team leadership abilities

• Knowledge of TNPCB/CPCB record formats and expectations

• Hands-on experience working in a hot & dusty atmosphere in a continuous running plants like Cement Plants – clinker, grinding, bag filters, kiln dust/Steel & Metallurgical Plants – coke ovens, sinter plants, blast furnaces/Power Plants (Coal-based) – fly ash, ESP/Bag filter dust/ Mining & Mineral Processing – crushing, grinding, screening/Carbon Black & Furnace Carbon Plants – very fine carbon dust/ Tyre Shredding & Pyrolysis Units – rubber dust, carbon black dust etc.

Authority Level:

• Direct authority over all pyrolysis unit operations and shift teams

• Approve shutdown/startup schedules and process changes (within policy)

• Raise maintenance work orders and spare part requisitions

• Recommend process improvements and escalate safety concerns