Resume - Smelter expert - ISA smelter; waste Heat Recovery Boiler (WHRB), DM Plant, Elect...

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Resume #88407

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Smelter Operations Boiler operation Sulfuric plant operation Project Management Quality Compliance Copper Concentrate Blending Metallurgical Management „H Smelting Chemistry „H Inventory Management DCS Operations

"Excels In Smelter -projects, Commissioning, Operation & Troubleshooting"

Synopsis:
MBA (Operations Management), performance driven and accomplished professional offering 16 years of experience including 14 years in Sterlite Copper and 2 years of International exposure in Mopani Copper Mines PLC, Zambia.
Well versed in Copper Extraction Metallurgy and ISA Smelter, Heat Recovery Boiler, Sulfuric Acid plant, Matt settling Electric Arc furnace, (MSEAF), Rotary Holding Furnace (RHF), Anode Furnace, Casting Wheel operations.
An efficient communicator possessing sound coordination, interpersonal, leadership, relationship & risk management, problem solving & troubleshooting and mentoring & motivating skills.
Currently Deputy Manager ¡V Smelter and sulfuric acid plant with Sterlite Copper, Tuticorin since Feb 2009.

Expertise in¡K
Planning and executing new smelter projects and successful commissioning of ISA Furnace, Waste Heat Recovery Boiler, Sulfuric Acid plant, Rotary Holding Furnace, PS Converters, Anode Furnace and Oxygen Plant.
Troubleshooting daily smelter issues; identifying & implementing de-bottlenecking projects for continual improvements and condition monitoring of ISA furnace, Sulfuric Acid plant, MSEF, Boilers, Anode, Slag Cleaning furnaces
Improving ISA feed rate, metallurgy & excellent process control, increasing plant availability & Improving Sulfuric plant availability and sulfur recovery, effluent treatment, converter blow charge size and reducing converter blow time & Copper Loss in granulated slag.
Formulating and controlling budgets, Formulating long term/short term strategic plans, Evaluating capital expenditure proposals, Liaising with Govt. Officials & local agencies,
Formulating, implementing and controlling Standard Operating Procedure (SOP) for total operations and Safty
Production planning and troubles shooting, formulating production targets and controlling the cost parameters.
Reviewing the operational practices, identify the areas of bottlenecks and work out system and process changes for qualitative and quantitative improvement
Planning and effecting preventive maintenance, executing cost saving and energy saving techniques to control O&M cost.
Over All Equipments Effectiveness ( OEE), Total Quality Management ( TQM).
Devising systems/ process changes for qualitative improvements in productivity & reducing rejection rate.
Formulating and Conducting Training and Developments Plans ( TDP)
Formulating and implementing Motivation & participation strategies for building effectiveness among team members.

Career Highlights

Sterlite Copper
Instrumental in the successful commissioning of the 4.4M diameter New ISA furnace, Waste Heat Recovery Boiler and 2 numbers of Rotary Holding Furnaces( RHF) & sulfuric Acid plant (2004)
Pivotal in the successful completion of 400kTPA smelter de-bottlenecking projects in compliance with time & budget (2006)
Successfully commissioned the 2.87 M diameter ISA furnace, Sulfuric Acid plant, RHF and Converters (1995)

Mopani Copper Mines
Resolved all metallurgical issues and optimized the availability of ISA Furnace including the feed rate into 100tph
Resolved all operational issues and optimize the availability of Sulfuric Acid plant to meet smelter availability
Introduced modern SS tuyers to all 4 converters and also introduced Auto Punching machine & continual leak test, arresting the leaks in tuyer body and gaskets, ensuring charge size enhancement from 80 tons to 110 tons by Mar 2008
Contributed in COP & improved operating efficiency like oxygen enrichment in ISA furnace, enhanced availability & operating efficiency in converters, introduced coal from coke and eliminated oil while on smelting

Career History

Sterlite Copper ¡V Tuticorin (June 1996 ¡V Jan 2007 & since Feb 2009 onwards)
Deputy Manager ¡V Smelter (Feb 2009 ¡V till date)

Career Growth
Deputy Manager ¡V Smelter & Acid plant (Feb 2009 ¡V till date)
Associate Manager ¡V Projects (April 2005 ¡V Jan 2007)
Engineer primary -smelter and Acid plant(Apr 2002 ¡V Mar 2005)
Control Room Operator (DCS) ISA Furnace & Acid plant (June 1996 ¡V Mar 2002)

Job Profile:
Joined Sterlite Copper (Unit of Vendata Resources and a leading copper smelter, using advanced technology of ISA FURNACE) as CRO (DCS), rose through various promotions to be Associate Manager
Rejoined as Deputy Manager ¡V Smelter in Feb 2009 and handled a wide range of responsibilities as mentioned below:

Deputy Manager ¡V Smelter & Acid plant
Leading a team of 180 personnel, reporting to the Manager ¡V Smelter and steered ISA Furnace, Waste Heat Recovery Boiler, sulfuric acid plant, PS Converter & Rotary Holding Furnace operation, Anode Furnace & Cast Wheel operations.
Involved in Copper recovery, Feed water mineralogy control, Slag chemistry control & process control and Revert management & revert treatment in ISA-250tpd.

Achievements:
Instrumental in ensuring 98% in over all availability of smelter.
Increased the SS lance life from 7 days average to 10 days average.
Effectively reduced the HFO consumption from 110 KL to 50 KL through modification of the lance tip.
Pivotal in enhancing the sulfur recovery from 94% to 97%.
Successfully trained 5 GETs on primary smelter operations and smelting chemistry and sulfuric plant operation.

Associate Manager ¡V Projects:
Led a team of 85 personnel, reported to the Manager ¡V Projects and involved in successful completion of the following 400,000 TPA-SMELTER de-bottlenecking projects.
Ware house extension for holding stock of additional 15000 MT.
Crane rail girder strengthening for 80T/80T
Converter pit deepening for handling of 7M3 ladle in blister transfer from 5M3 ladle
Evaluation, selection, Erection and commissioning of 2 new EOT 80T/80T cranes to increase the crane logistics
Evaluation, selection of 7 numbers of 10M3 ladles for Matt handling and changing the exiting 7M3 Ladle for blister transfer to improve the crane logistic & production and reduce the stack out time
Dismantling one 60T EOT CRANE
Erection and commissioning new PRDS SYSTEM for handling of incremental of 10T steam WHRB
Upgrading of SLAG CLEANING FURNACE (SCF) by replacing the supply and return pipelines into 500NB from 350NB and upgrade the all pumps into 750M3/HR from 600M3/HR to increase the granulation rate
Evaluating, selection, erection and commissioning of one plant air compressor 7500m3/hr @ 7.5kg/cm2 and one air dryer 3000M3 /hr
Project evaluation, project management and commissioning of GAS COOLING AND GAS CLEANING SECTION-primary Dyna-Wave Scrubber, Gas cooling tower, weak acid coolers, secondary Dyna-wave scrubber, week Acid Stripping Tower, Mist precipitator, suction seal, safety showers
Project evaluation, project management and commissioning of STRONG ACID SECTION- Drying tower system, Absorption tower system, drying and Absorption Acid coolers, Acid strainers, Product acid cooler and pumps, Strong acid area sump pumps,
Project evaluation, project management and commissioning of COOLING WATER SYSTEM- cooling towers and pumps, Side stream filters.
project evaluation, project management and commissioning of GAS OXIDATION SYSTEM- dilution air filter, drying tower, So2 Gas blower, Cold heat exchanger, hot heat exchanger, SO2 converter, secondary pass cooler, SO3 cooler, Absorption tower, stack and start-up pre-heater.
Project evaluating and identification of 1000TPD Oxygen plant

Achievements:
Received an award of 1100 options of VEDANTA RESOURCES listed in LSE for outstanding performance delivery from the company Chairman (Feb 2006).
Received appreciation from CEO and monetary reward of Rs. 30K for successful completion of the 4LTPA SMELER de bottlenecking projects within assigned time period of 15th Sep 2006 (Oct 2006).

Engineer:
Led a team of 50 personnel and reported to the Associate Manager
Controlled ISA furnace, Sulfuric Acid plant, RHF & Boiler operations including bath metallurgy, temperature & process control.
Accountable for achieving the assigned production targets, blending of concentrate and copper recovery.
Improved product quality, ensured compliance with hygiene norms and trained team members.

Achievements:
Recognized for special contribution in power conservation in Slag Granulation Pumps.
Received appreciation letter from the company President and rewarded with a cash award of Rs.50 K (Jul ¡VSep 2003).
An active member of successful TQM Projects on "Increase the brick champion life of R.H.F into 2.5 years" and awarded as best TQM.
Received a CEO Kit of Rs. 200K for contribution in the successful commissioning of 3 lac tons / annum new ISA furnace, 2 RHFs and Boiler (Jun 2005)
Received a CEO Kit of Rs. 25K for the special contribution in copper Loss in RHF granulated slag (Feb 2004)
Received Employee of the Month Award for Apr 2002 for increasing feed rate into 90TPH by enriching O2 into 85%.

Control Room Operator:
Led a team of 25 personnel, reported to the Engineer and controlled the Operating Parameters of ISA furnace & Sulfuric Acid plant by DCS / CS 3000.
Involved in handling the Process control in ISA, Sulfuric Acid plant & RHF (Rotary holding furnace), slag chemistry control, matt grade control, draught control and bath temperature control
Meeting converter demand by optimizing feed rate and providing advice on maintenance.
Responsible for monitoring Lance life, HFO consumption including condition monitoring of furnace.

Achievements:
Recipient of the "Employee of the Month" Award for Oct 1999 for increasing the enrichment of O2 in ISA furnace from 60 % to 80% to increase the feed rate from 65 TPH to 80TPH.
Received Employee of the Month Award for Sep 1998 for optimizing the revert feeding ISA furnace from 5 TPH -15 TPH.
An active member of the Quality Improvement Project on reducing losses in Storage and handling raw materials by TQM Methodology (1997-1998)

Previous Assignments

Mopani Copper Mines PLC - Zambia
Assistant Superintendent ¡V Smelter (Feb 2007 ¡V Jan 2009)

Job Profile:
Led a team of 195 personnel and reported to Manager ¡V Smelter.
Involved in Concentrate blending and Slag chemistry control & process control in ISA Furnace, Sulfuric Acid plant and MSEF (Matt Settling Electric Furnace).
Monitored ISA Furnace, Sulfuric acid plant & MSEF (Matt Settling Electric Furnace) operations including Boiler, feed water mineralogy control, Anode furnace & cast wheel and scrap melting furnace operations.
Production planning, Copper recovery, improving product quality and ensuring high availability and utilization of plant and equipment in smelter including maintaining compliance with the health, safety and environment policies.
Revert management & revert treatment, budgeting & cost control, achieving production targets, advising on maintenance issue and training team members on process and slag chemistry.

Achievements:
Increased the copper recovery from 85% - 97% by treating reverts from 0 TPD to 300TPD by Aug 2007.
Developed 7 DCS operators for ISA furnace, Sulfuric Acid Plant & boiler operation by Jul 2007
Successfully attained the design capacity ISA furnace in MCM of feed rate (100tph from 70tph) by Jul 2007
Successfully attained the design Capacity of Acid plant in MCM (850tons per day) by Jul 2007
Increased the operating efficiency of ISA furnace from 62% to 90% by Jul 2007
Increases the operating efficiency of Acid plant from 74% to 92% by Jul 2007
Increased the copper production to 17,000 MT/ Month from 10,000 MT/Month since Jul 2007
Effectively treated the accumulated mixed concentrate of around 10,000 tons by Jul 2007
Increased oxygen enrichment from 55% - 90% and reduced steam generation from 40 to 31 TPH to reduce the feed water consumption, ensuring 62% - 90% enhancement in the ISA availability in Mopani Copper Smelter
Increased the charge size from 80tons per blow into 110 tons per blow in PS Converters in Mopani Copper Smelter
Increased the scrap treatment from 2500 tons per month to 4000 tons per month in the scrap melting furnace in Mopani Copper Smelter
Reduced the anode rejection rate into 4% from 7% in Mopani Copper Smelter

Sterlite Industries (I) Ltd. (JFTC) ¡V Aurangabad
Production Supervisor (May 1993 ¡V May 1996)

Job Profile:
Joined as a Production Supervisor in JFTC (Copper Telecom Cable Unit), led a team of 12 personnel and reported to Asst. Mgr ¡V Production.
Involved in monitoring the production operations in Tandem Lines, Cabling, Sheath Lines and Jacketing Lines.

Technical Visits

Technology / Plant Location Period
Ero-African Mine Meet Lushaka, Zambia 2008
Mount ISA Technology Meet Madurai, India 2006
Ausmelt Technology - Lead Smelter Hindustan Zinc, Udayapur, India Sep 2005
ISA Technology ¡V Mount ISA Mines MIM, Australia Oct 2001

Professional Trainings

Title Person / Organization Location Period
Over all Equipments Effectiveness (OEE) Total Quality Consultant Madras July 2005
Operations Waste Heat Boiler Hindustan Zinc Udayapur Mar 2005
Operation Management QUMPRO Mumbai Jun 2002
CS3000 Fundamentals Yokogawa Blue Star Bangalore Jul 2000
Total Quality Management (TQM) QUMPRO Mumbai Jan 1998
ISA Furnace, Sulfuric Acid plant and R.H.F Operation ¡V Inplant Training Mark Prince, Mathew Pratt & AUSAFE Australia Aug-Dec 1996

Educational / Professional Qualifications

MBA ( Operation Management), Madurai Kamaraj University (2001)
B.Sc (Chemistry), Madurai Kamaraj University (1991) first class

Personal Particulars

Date of Birth: 5th February 1971
Languages: English, Hindi and Tamil

References:
Will be provided

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