Pf Process

**Designation**:Engineer

**Updated**:December 20, 2024

**Location**:Andhra Pradesh, India

**Organization**:Cement

**Job Purpose**:
To Plan, implement and review in consultantion with DH Process and DH QC such as identification of suitable AFR material & waste materials through lab testing, unloading & storage and feeding the material through pre processing& co processing in order to achieve a suitable substitutes of fossil fuels & natural raw materials.

**Job Context & Major Challenges**:
Job Context:
Balaji Cement Works is located 200 km from Hyderabad, around 12 km from National Highway No 65. It has cement manufacturing capacity of 5 MTPA and Clinker capacity of 3.6 MTPA (Kiln rated capacity 10,000 TPD). Entire grinding capacity is at one location.
Limestone requirement of the unit is 6.0 MTPA. To meet the limestone requirement, Budawada Limestone Mine is spread over 629.22 Ha Job Context:
Balaji Cement Works is located 200 km from Hyderabad, around 12 km from National Highway No 65. It has cement manufacturing capacity of 5 MTPA and Clinker capacity of 3.6 MTPA (Kiln rated capacity 10,000 TPD). Entire grinding capacity is at one location.
Limestone requirement of the unit is 6.0 MTPA. To meet the limestone requirement, Budawada Limestone Mine is spread over 629.22 Ha having deposits sufficient for around 60 years. Two limestone crushers with capacity of 900 TPH each, located inside unit, 2.7 km from mine. Material is transported from mine to unit through dumpers.
Unit has two captive thermal power plants of 35 MW and 22.5 MW each in addition to 15 MVA grid power connection with SEB to cater the entire power requirement of the unit. The unit has private railway siding for its inbound/ outbound material/fuel/cement & clinker movement. There is 12 KM water pipe line from Krishna River to unit to meet the water requirement of unit and township.

The position is responsible for compliance of statutory requirements including PCB norms & safety requirements.. This position also responsible to take preventive and corrective measures to minimize any advarce impact of process quality, emission & Health including maintaining required documents & records and MIS.

Job Challenges:
• Ensuring the safety of people, protection of environment due to handling and processing of wide variety of waste materials.
• Ensuring the process requirements due to various type of materials having changing characteristics in terms of physical and chemical properties.
• Ensuring Statutory requirements due to stringent acts and rules imposed by the regulatory bodies.

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

**Supporting Actions (Max 1325 Characters)**
- KRA1
- 1. Planning and coordination
To plan, coordinate and monitor all operations of Alternate Fuel & Raw Material including its Laboratry, unloading, Preprocessing & Co-processing.
- • Coordinate with vendors and source required AFR
• Interpret the test results and decide suitable actions for usage of AFR.
• Implement AFR QC plan by organizing all related activities.
• Preserve samples for re-verification by customers.
• Conduct testing at Plant’s AFR Lab or organize testing at advanced labs located at other group Units.
• Co-ordinate with all the concerned persons to implement actions based on test results for smooth feeding of AFR.
• To coordinate with Maerials department for vendor development
• To check all vendors comply with safety norms
- KRA2
- 2)To co-ordinate for smooth function of AFR with AFR HO, Accounts & material department regularly.
- • To coordinate with HO for AFR Contracts / Agreements
• To coordinate with Maerials Department for arrangeing AFR as per terms of Contracts/Agreement
• To coordinate with Accounts and ensure payment of vendors as per Agreement/Contract terms
- KRA3
- 3)Statotory Complaince
Ensure usge of AFR material as per CPCB/TNPCB norms and complied.
- • Close Co-ordinate with HOD (Process) and Waste Generators and schedule the trial run.
• Obtain permits for transportation and disposal of wastes from State Pollution Control Board, file returns on waste usage, carry out periodic emission measurements in compliance with the permits obtained.
• Ensure safety during transportation, storage, testing and pre-processing of hazardous wastes.
• Develop SOPs, preventive measures, checks and required
• Obtain trial run permissions.
• Appoint third party agency authorised by CPCB for monitoring.
• Ensure successful execution of trial run.
• Provide required data/information to third party agency for preparing the report and submit the same to SPCB on time.
- KRA4
- 4.System implementation:
(Effective implementation of all IMS and other systems requirements through involvement for continuous improvement in plant working condition & quality standards)
- Execution of counter measures recomme