Manager Production (Integrated Cement Plant)

Sarthee Consultancy; Delhi; On-site; INR 600,000 - 1,200,000; Full time

Job summary

Sarthee Consultancy seeks a seasoned cement plant process engineer to lead technical and operational excellence across the raw mill, kiln, and cement grinding sections. You will optimize heat balance, raw mix design, and combustion efficiency while coordinating cross-functional teams for on-time production and quality targets.

Expertise in VRM/ball mill operation, refractory selection, and dust collection systems is essential for improving clinker quality and plant reliability.

Qualifications

• BSc Chemistry or BE Chemical is required.
• Deep knowledge of raw mix design, heat and mass balance.
• Experience with kiln pyro-processing and clinkerization chemistry.
• VRM and ball mill operation and optimization.
• Familiarity with refractory selection and grinding media optimization.
• Understanding of dust collectors, ESPs and bag filters.
• Knowledge of ISO 9001/14001/45001 systems and cement quality standards.

Responsibilities

• Coordinate daily to annual production targets for limestone crushing, raw mill, kiln and cement grinding.
• Optimize kiln feed chemistry to maintain stable operation and clinker factors.
• Drive reliability and output improvements for plant sections.
• Collaborate with Mines, Maintenance, Quality, Purchase and Finance teams.

Skills

Raw mix design

Heat & mass balance

Kiln pyro-processing

Clinkerization chemistry

VRM operation

Ball mill optimization

Coal mill operation

Clinker cooler efficiency

Refractory selection

Grinding media optimization

Dust collection systems

Alternative fuels & TSR

QCX / Laboratory systems

DCS/PLC based process control

Cement quality standards

ISO 9001 / 14001 / 45001 systems

Education

BSC Chemistry or BE Chemical

Tools

QCX / Laboratory systems

DCS/PLC process control

Job description

Education

• BSC Chemistry or BE Chemical

Technical & Process Expertise

• Deep knowledge of:
  • Raw Mix design & proportioning
  • Heat & Mass Balance calculations
  • Kiln pyro-processing & clinkerization chemistry
  • VRM and Ball Mill operation & optimization
  • Coal mill operation and fuel optimization
  • Clinker cooler efficiency improvement
• Strong understanding of:
  • Refractory selection, installation & performance monitoring
  • Grinding media optimization
  • Dust collectors, ESPs & Bag Filters
  • Alternative fuels & thermal substitution rate (TSR)
• Working knowledge of:
  • QCX / Laboratory systems
  • DCS/PLC based process control systems
  • Cement quality standards & statutory norms
  • ISO 9001 / ISO 14001 / ISO 45001 systems

Operational & Leadership Capabilities

• Strong cross-functional coordination with:
  • Mines
  • Maintenance (Mechanical + E&I)
  • Quality Control
  • Purchase & Stores
  • Finance
• Proven track record of:
  • Reducing Heat Consumption (kCal/kg clinker)
  • Reducing Power Consumption (kWh/ton cement)
  • Increasing Kiln availability & output
• Budget preparation and cost optimization skills.
• Strong MIS, ERP and KPI monitoring capability.

Production Planning & Execution

• Ensure daily, monthly & annual production targets for:
  • Limestone crushing
  • Raw Mill
  • Kiln & Pyro section
  • Cement grinding
• Optimize kiln feed chemistry and ensure stable operation.
• Maintain clinker factor and cement blending targets.
• Coordinate closely with Mines team for raw material availability and quality alignment.
• Ensure plant runs at optimum rated capacity with maximum reliability.