Senior Manager / Manager Coke Oven & CDQ Operation

Sarthee Consultancy; India; On-site; INR 3,000,000 - 6,000,000; Full time

Job summary

Sarthee Consultancy is seeking an experienced Coke Oven and CDQ operations leader to oversee battery operations, CDQ system performance, and process control in a large steel plant. You will coordinate with maintenance, process control, and utility teams to ensure stable pressure, temperature uniformity, and efficient heat recovery.

The role requires hands-on leadership of shift in-charges, engineers, and operators, planning 24x7 rosters, driving safety compliance to ISO standards, and delivering

Qualifications

• BE/B.Tech in Metallurgical, Mechanical, Chemical, Electrical, or Production Engineering from a recognized institution.
• Manager: 8-12 years of Coke Oven and CDQ operations experience in integrated steel plants.
• Senior Manager: 12-16 years of experience including process control, operation, and maintenance coordination in coke plants.
• Experience with large capacity coke ovens (above 0.5 MTPA) and energy recovery preferred.

Responsibilities

• Manage the entire Coke Oven battery operation: charging, coking, pushing, and quenching.
• Ensure stable oven pressure, temperature uniformity, and adherence to coking time norms.
• Optimize coal charge quality, blend ratio, and moisture content for consistent coke strength (CSR, CRI).
• Coordinate with Coal Handling Plant and By-Product Plant to ensure continuous input/output flow.
• Prevent battery leakages, oven damage, and ensure proper carbonization.
• Plan and execute oven heating-up, repair, and maintenance shutdowns with maintenance teams.
• Supervise CDQ system operation to recover heat and generate steam or power.
• Maintain control over coke temperature at CDQ inlet/outlet, circulating gas temp, pressure, and flow.
• Optimize steam generation and waste heat recovery efficiency.
• Monitor CDQ boiler, fans, gas circulation system, dust collectors, and cooling towers.
• Coordinate with Power Plant Utility Team on steam/power balance.
• Troubleshoot gas leaks, dust accumulation, coke breakage, and uneven cooling.
• Analyze daily production data, coke quality, and CDQ performance to identify deviations and optimize parameters.
• Support process trials for energy efficiency improvements and enhanced coke quality.
• Collaborate with process control and automation teams to fine-tune DCS logic and instrumentation.
• Implement best practices to minimize fuel consumption and maximize waste heat recovery.
• Support digital monitoring systems (SCADA/DCS) for real-time control.
• Participate in planned and preventive maintenance activities with Mechanical, Electrical, and Instrumentation teams.
• Ensure high equipment availability for charging cars, pushers, quenchers, CDQ boilers, fans, valves, cyclones, and conveyors.
• Prepare and execute shutdown and maintenance schedules.
• Analyze equipment performance and implement reliability improvement strategies.
• Enforce compliance with all safety and environmental standards in Coke Oven and CDQ operations.
• Promote PPE usage, confined space entry, and LOTO protocols.
• Minimize fugitive emissions, dust, and gas leakages.
• Drive safety culture through training, toolbox talks, and incident reporting.
• Support ISO 45001, ISO 14001, and ISO 9001 standards.
• Lead and manage a team of Shift In-charges, Engineers, and Operators.
• Plan manpower and roster for 24x7 operations.
• Conduct skill development sessions on safe and efficient operation.
• Drive team performance through motivation and KPIs.
• Maintain accurate daily and monthly reports on coke production, quality, CDQ performance, heat recovery, equipment downtime, and maintenance schedules.
• Support audit processes and management reviews with precise data reporting.
• Prepare deviation analysis and develop action plans for process improvements.

Skills

Coke Oven Operations

CDQ Operations

Process Control

Maintenance Coordination

Safety Compliance

Team Leadership

Documentation & Reporting

Education

BE/B.Tech in Metallurgical, Mechanical, Chemical, Electrical or Production Engineering

Tools

SCADA/DCS systems

ISO Standards Knowledge

Job description

Role & responsibilities

Key Responsibilities

Coke Oven Operation Management

• Manage the entire Coke Oven battery operation: charging, coking, pushing, and quenching.
• Ensure stable oven pressure, temperature uniformity, and adherence to coking time norms.
• Optimize coal charge quality, blend ratio, and moisture content to maintain consistent coke strength (CSR, CRI).
• Coordinate with Coal Handling Plant and By-Product Plant to ensure continuous input and output flow.
• Prevent battery leakages, oven damage, and ensure proper carbonization.
• Plan and execute oven heating-up, repair, and maintenance shutdowns in coordination with maintenance teams.

CDQ System Operation

• Supervise CDQ system operation to recover heat from hot coke and generate steam or power.
• Maintain control over coke temperature at CDQ inlet and outlet, circulating gas temperature, pressure, and flow.
• Optimize steam generation and waste heat recovery efficiency.
• Monitor CDQ boiler, fans, gas circulation system, dust collectors, and cooling towers.
• Coordinate with Power Plant Utility Team on steam and power balance.
• Troubleshoot abnormalities including gas leaks, dust accumulation, coke breakage, and uneven cooling.

Process Control and Optimization

• Analyze daily production data, coke quality, and CDQ system performance to identify deviations and optimize parameters.
• Support process trials for energy efficiency improvements and enhanced coke quality.
• Collaborate with process control and automation teams to fine-tune DCS logic and instrumentation.
• Implement best practices to minimize fuel consumption and maximize waste heat recovery.
• Support digital monitoring systems (SCADA/DCS) for real-time control.

Maintenance and Equipment Reliability

• Participate in planned and preventive maintenance activities with Mechanical, Electrical, and Instrumentation teams.
• Ensure high equipment availability for charging cars, pushers, quenchers, CDQ boilers, fans, valves, cyclones, and conveyors.
• Prepare and execute shutdown and maintenance schedules.
• Analyze equipment performance and implement reliability improvement strategies.

Safety, Health, and Environment

• Enforce compliance with all safety and environmental standards in Coke Oven and CDQ operations.
• Promote PPE usage, confined space entry, and LOTO protocols.
• Minimize fugitive emissions, dust, and gas leakages.
• Drive safety culture through training, toolbox talks, and incident reporting.
• Support ISO 45001 (Occupational Health), ISO 14001 (Environment), and ISO 9001 (Quality) standards.

Team Management and Training

• Lead and manage a team of Shift In-charges, Engineers, and Operators.
• Plan manpower and roster for 24x7 smooth operations.
• Conduct skill development sessions on safe and efficient operation.
• Drive team performance through motivation and effective KPIs.

Documentation and Reporting

• Maintain accurate daily and monthly reports on coke production, quality, CDQ performance, heat recovery, equipment downtime, and maintenance schedules.
• Support audit processes and management reviews with precise data reporting.
• Prepare deviation analysis and develop action plans for process improvements.

Preferred candidate profile

Qualifications and Experience

• B.E./B.Tech in Metallurgical, Mechanical, Chemical, Electrical, or Production Engineering from a recognized institution.

• Manager: 8-12 years of experience in Coke Oven and CDQ operations within integrated steel plants.
• Senior Manager: 12-16 years of experience including process control, operation, and maintenance coordination in coke plants.
• Experience with large capacity coke ovens (above 0.5 MTPA) and energy recovery preferred.