Plant Head - Integrated DRI Steel Plant

Role Of Plant Head

1. Strategic Leadership

• Define long-term and short-term operational strategies to align with the organization's goals.
• Establish a clear vision for productivity, safety, and sustainability.
• Oversee plant expansion, capacity enhancement, and modernization projects.

2. Plant Operations Management:

• Oversee the smooth functioning of rotary kilns, coal-based DRI production.
• Ensure efficient reduction of iron ore to produce high-quality sponge iron, meeting metallization targets.
• Ensure efficient production of high-quality products, adhering to customer specifications and industry standards.
• Optimize raw material usage (iron ore, coal, scrap, etc.), energy consumption, and minimize waste.
• Optimize the usage of raw materials such as iron ore, coal, dolomite, and additives.
• Implement efficient handling and storage of raw materials and sponge iron to minimize losses.

3. Process Integration:

• Oversee seamless integration of various units like DRI kilns, melting (EAF/IF), rolling mills, and auxiliary facilities.
• Track and analyze KPIs like yield, downtime, and operational efficiency.
• Monitor critical process parameters (temperature, retention time, air injection, etc.) to ensure optimal kiln performance.
• Troubleshoot kiln issues such as ring formation, clinker build-up, or accretion.

4. Maintenance and Reliability

• Equipment Management: Ensure the timely maintenance of equipment, reducing downtime and breakdowns.
• Reliability Programs: Implement predictive and preventive maintenance practices.

5. Technology and Innovation

Process Improvement: Drive initiatives to improve production processes through automation, digitization, and Lean practices.

Technology Adoption: Stay updated on emerging technologies and implement relevant ones (e.g., advanced DRI technology, waste heat recovery systems).

6. Financial and Cost Control

• Prepare and manage the plants operational budget, including CAPEX and OPEX.
• Identify areas to reduce production costs without compromising on quality or safety.
• Improve the plants profitability by enhancing production efficiency and reducing down-time.

7. Safety and Compliance

• Ensure adherence to environmental, labor, and safety regulations at the state and national levels.
• Implement robust safety programs to prevent accidents and ensure a safe working environment.
• Monitor pollution control measures and ensure compliance with pollution norms (e.g., air and water quality standards).

8. Reporting and Communication

• Present periodic reports to top management on plant performance, challenges, and improvement plans.
• Provide strong leadership during crises, such as breakdowns, shortages, or accidents.

9. Administrative control:

• Exercise control over all the activities, be it related to any department within the plant premises.
• Track & control the actions of all HODs and channelize them for betterment of Plant
• Maintain liaison with all concerned authorities- both Central and State governments.

EDUCATIONAL BACKGROUND:

Regular Bachelors degree in Metallurgical, Mechanical, or Chemical Engineering (mandatory). [Candidates having BE / B.tech degrees through distance courses and Diploma Holders may excuse].

MBA or advanced management qualification (preferred).

EXPERIENCE:

• 25+ years of experience in similar steel plant operations with at least 5 years in a senior leadership role.
• Deep understanding of DRI-based steelmaking processes.
• Executive at the verge of superannuation or just superannuated from SAIL & RINL, shall be given due preferences.

SKILLS :

• Strong technical knowledge of DRI, Electric Arc Furnaces (EAF), Induction Furnaces (IF), and Rolling Mills.
• Leadership and team management skills.
• Financial and cost-management expertise.