Process Engineer

Job Title:

Process Engineer – Activated Carbon Plant

Location:

Ponnapuram Village, Dharapuram Taluk, Tirupur District, Tamil Nadu

Company Overview:

Carbonmax Advantech Pvt Ltd is a leading manufacturer of coconut shell-based steam activated carbon with end-to-end infrastructure including granulation, rotary kiln-based activation, post-activation refining, and value-added product units such as acid-washed, powdered, impregnated, pelletized, and catalytic carbon. With a strong focus on process reliability, energy efficiency, and product consistency, Carbonmax is evolving into a global player in high-performance activated carbon solutions.

Position Summary:

We are looking for a Process Engineer to drive efficient and optimized operations across the activated carbon manufacturing line. The candidate will oversee process parameters from charcoal feedstock to post-activation refining, ensuring stable yields, proper equipment operation, thermal balance, emission control, and integration of instrumentation and automation.

This role demands strong technical expertise in rotary kiln operation, steam process systems, yield tracking, stack monitoring, and process instrumentation, with a focus on industrial sustainability and product uniformity.

Key Responsibilities:Feedstock Handling & Granulation:

• Assess incoming charcoal grades, ash content, size distribution, and moisture.
• Manage granulation, dust extraction, charcoal cleaning, and crushing operations.
• Coordinate material flow from feedstock yard to kiln feed conveyor.

Activation & Kiln Process Control:

• Monitor and control rotary kiln operations including:
• Feed rate, temperature zones, rotation speed, steam injection.
• Activation temperature profiles and residence time consistency.
• Integrate kiln draft controls: manage natural draft and ID fan-based mechanical draft.
• Supervise waste heat recovery boiler (WHRB) operation and steam generation efficiency.

Process Instrumentation & Automation:

• Calibrate and monitor temperature sensors, pressure gauges, flow meters, level controllers.
• Support SCADA/PLC-based control systems and process data logging.
• Ensure preventive maintenance and troubleshooting of process instrumentation.

Post-Activation & Product Handling:

• Manage downstream systems:
• Destoner, RMC Crusher, Rotex Screener, MPE Crusher, Vibratory Screener, Blender.
• Track throughput, particle size distribution, and carbon blending for target specs.

Steam System & Boiler Water Quality:

• Operate and monitor WHRB and auxiliary boilers for continuous steam supply.
• Maintain dosing systems to manage boiler water chemistry (pH, hardness, oxygen).
• Ensure safe and efficient condensate recovery and steam utilization.

Process Yield & Emission Monitoring:

• Track input vs. output yields, process losses, and energy consumption metrics.
• Monitor stack emissions; maintain settling chamber and dust control systems.
• Support environmental compliance with TNPCB and internal audit protocols.

Troubleshooting & Continuous Improvement:

• Analyze process deviations using root cause analysis (RCA).
• Recommend and implement process improvement measures (Kaizen, 5S, Lean).
• Collaborate with QA, maintenance, and production teams for cross-functional efficiency.

Eligibility Criteria:Qualification:

• B.E. / B.Tech in Chemical Engineering, Mechanical Engineering, Process Engineering, or related field.
• Training or certification in thermal systems, instrumentation, or process automation is a plus.

Experience:

• 5–10 years in process engineering roles within:
• Activated Carbon / Cement / Ceramics / Kiln-based or Thermal Process Industries.
• Hands-on expertise in rotary kiln control, steam systems, and yield optimization.

Technical Skills:

• Rotary kiln process dynamics and steam injection control.
• WHRB and auxiliary boiler operations with dosing pumps.
• Stack draft management and environmental compliance.
• Familiarity with instrumentation (sensors, transmitters, PLC/SCADA).
• Material handling and particle sizing equipment operation.

Language:

• Tamil (mandatory), English (working), Hindi (preferred)

Software Skills:

• Process monitoring systems (SCADA/PLC)
• MS Excel, process reports, and data analytics tools

Key Competencies:

• Process troubleshooting and root cause analysis
• Yield and energy balance tracking
• Coordination with QA, maintenance, and production teams
• Process documentation and SOP adherence
• Strong floor-level presence and execution mindset

Reporting To:

Senior Manager – Plant Operations & Engineering

Employment Type:

Full-time | On-site (Ponnapuram Plant)

Compensation & Benefits:

• Salary commensurate with experience
• Performance-based incentives
• Statutory benefits and medical insurance
• On-site accommodation and canteen facility

Schedule:

• Day Shift
• Monday to Saturday (occasional weekend availability)

Supplemental Pay:

• Performance bonus
• Annual bonus
• Overtime pay (where applicable)

Ability to Commute/Relocate:

• Ponnapuram, Dharapuram Taluk: Must be able to relocate or commute reliably. On-site accommodation available.

How to Apply:

Send your updated CV to: hr.factory@carbonmaxtech.com
Subject: “Application – Process Engineer – Activated Carbon”
Speak with us: +91 99434 99855

Job Types: Full-time, Permanent

Pay: ₹22,000.00 - ₹35,000.00 per month

Benefits:

• Commuter assistance
• Food provided
• Health insurance
• Provident Fund

Schedule:

• Day shift
• Monday to Friday
• Weekend availability

Supplemental Pay:

• Yearly bonus

Ability to commute/relocate:

• Dharapuram, Tamil Nadu: Reliably commute or planning to relocate before starting work (Preferred)

Work Location: In person