Pf Process

**Designation**:Assistant Manager

**Updated**:January 13, 2025

**Location**:Gujarat, India

**Organization**:Cement

**Job Purpose**:
To support SH Post Clinkerisation in Operation of Cement Mills of Line No. I & II along with feeding circuit and fly ash dossing system, as well as identify and reporting of any abnormality in operation for Smooth operation to meet the production, specific power consumption targets and quality targets at optimum cost maintaining environment and safety standards.

**Job Context & Major Challenges**:
Kiln Capacity '“ 4000 TPD
Job Context:
UltraTech Cement Limited is the cement flagship company of the Aditya Birla Group. A USD 7.9 billion building solutions powerhouse, UltraTech is the largest manufacturer of grey cement, ready mix concrete (RMC) and white cement in India. It is the third largest cement producer in the world, excluding China. UltraTech is the only cement company globally (outside of China) to have 100+ MTPA of cement manufacturing capacity in a single country. The Company's business operations span UAE, Bahrain, Sri Lanka and India.

UltraTech has a consolidated capacity of 138.39 Million Tonnes Per Annum (MTPA) of grey cement. UltraTech has 23 integrated manufacturing units, 29 grinding units, one Clinkerisation unit and 8 Bulk Packaging Terminals. UltraTech has a dealer network of over 30,000 and retailer network of over 84,000 across the country, with a market reach of more than 80% Indian cities and towns. In the white cement segment, UltraTech goes to market under the brand name of Birla White. It has one White Cement unit and three Wall Care putty unit, with a current capacity of 1.98 MTPA. With 230+ Ready Mix Concrete (RMC) plants in 100+ cities, UltraTech is the largest manufacturer of concrete in India. It also has a slew of speciality concretes that meet specific needs of discerning customers. Our Building Products business is an innovation hub that offers an array of scientifically engineered products to cater to new-age constructions.

Narmada Cement - Jafarabad Works was established in 1982 as Narmada Cement Company Limited and merged with UltraTech in 2006. The installed capacity of 1 MMTPA clinker has been gradually increased to 1.50 MTPA (4,300 '“ 4,500 TPD). Cement capacity is 0.50 MTPA (1,150 TPD).
It is India's first split location dry process cement plant with Fuller technology having four-stage suspension pre
- heater, in-line flash calciner, reverse air bag house dust collector, vertical roller mills besides to be the first to unload imported South African coal at plant jetty. It transports 100% clinker to grinding units is in bulk by sea route. The special feature of this plant is '˜Just in Time' design for raw mill circuit. As against conventional norms of 20,000 MT silo for raw meal storage it has 2,000 MT silo.

The grinding units associated with Jafrabad Cement Works are Magdalla Cement Works and Ratnagiri Cement Works. All three coast-based split location clinker manufacturing units have jetties. Narmada Cement was the prime supplier of fly ash-based Portland Pozzolana Cement (PPC) to Sardar Sarovar Dam on river Narmada, which is the World's second largest concrete gravity dam (by volume).

Narmada Cement Mine is the captive mine for Jafarabad plant having a production capacity of 2.30 MTPA. It is situated near coastal village of Babarkot, 7 km from Jafarabad port. Out of the total 565.94 hector lease area.

Job Challenges:
1. Reduction of mill power consumption by improving mill output (rate of cement mills).
2. Reduction in mill tripping specially in rainy season and to maintain optimum production.

**Key Result Areas**:
**KRA (Accountabilities) (Max 1325 Characters)**

**Supporting Actions (Max 1325 Characters)**
- KRA1
- 1.Production & Quality cement
(Supervise Cement Mills operation for smooth optimum process operating conditions to achieve the targetted Production &
Quality
- 1.Check operation parameters of all equipments in the beginning of the shift.
2.Identify abnormalities if any Inform PF process and site attendants for corrective actions
3. Continuously monitor process parameters of raw mill and Register operational parameters of raw mill in log book as per the specified timelines with remarks if any
4. Check quality parameters for operation of raw mill.
6. Inform PF/ SH for any major abnormality / breakdown
7. Perform Corrective action as per instructions of SH (Process) / HOD (process)
8. Coordinate with all service departments & communicate plan problems if any for corrective actions.
9. Record shift wise production and quality of raw mill and Inform SH / HOD (Process) for production at the end of the shift
8)Preparing daily production report and filled up in SAP.
- KRA2
- 2.Cost Optimisation and Control
(Identify and analyse various process inputs and parameters like power etc., for cost reduction and ensure cost effective plant operation.)
- 1.Sp.Power consumption To avoid Idle running of the circuit,
2.Optimizing o