Senior Process Engineer

at  Heidelberg Materials

The role holder is responsible for

• Monitor and optimize the kiln and cement lines, from raw materials to finished product.
• Improve the operating efficiency of the pyro, comminution and associated equipments - to include reduction of air usage and false air, reduction of electricity and fuels, increasing alternative fuels, increasing alternative raw material consumption, reduction of water usage.
• Report to management team on performance against KPIs and other key metrics
• Set process related targets for operational staff
• Design and implement progressive, costed and planned improvements to the mills and kiln efficiencies; to include mill and kiln inspections and associated studies
• Develop and train staff in kiln and comminution process to put in place skills for the future business needs
• Verify that equipment is maintained in the proper original condition
• Verify that equipment is being operated in accordance with the OEM recommendations or as per Plant Manager/HOPExUK recommendations
• The reporting and accuracy of all process related KPI data and other internal reports as required
• The completion of regular kiln and cement line process inspections and the keeping of accurate records at a frequency agreed with the plant manager and head of operational excellence.
• Improving and optimising the process based on the above and other process data
• Providing solutions for operational problems
• Gathering, collating and analysing process and downtime information on kiln line and cement mills and associated equipment
• Monitoring and reporting on the consumption of raw materials, fuel, power, water and air.
• Working with departmental teams to identify and implement efficiencies in the consumption of fuel, power, water and air.
• Writing, maintaining, communicating and training SOPs for the Comminution and Pyro lines and ensure that reviewed on yearly basis.
• Conducting Heat and Mass Balance for Comminution and Pyro lines
• Taking full responsibility to achieve +95% of process optimiser utilisation (Expert system)
• Designing and implementing progressive, costed and planned improvements to the kiln and cement line efficiencies
• Assisting other departments in reaching operational targets
• Sharing best practice with other Heidelberg Materials cement plants on comminution and Pyro operation
• Performing any other process efficiency related duties as reasonably required by line management
• Providing ongoing operational support to the plant for all shifts by participating in the plant’s on call program. This includes evaluating and determining the course of action for incidents after hours and on weekends while on call and may require on-site supervision of the resolution to maintain operational efficiency
• Actively involve during all the Plant shutdowns and support production team to achieve all the tasks including refractories requirement and installation.
• Assessing potential alternative raw material, fuels and additives for improvements to improve the efficiency and cost reductions via trials.
• Support project implementation by taking the process lead

• Monitor and optimize the kiln and cement lines, from raw materials to finished product.
• Improve the operating efficiency of the pyro, comminution and associated equipments - to include reduction of air usage and false air, reduction of electricity and fuels, increasing alternative fuels, increasing alternative raw material consumption, reduction of water usage.
• Report to management team on performance against KPIs and other key metrics
• Set process related targets for operational staff
• Design and implement progressive, costed and planned improvements to the mills and kiln efficiencies; to include mill and kiln inspections and associated studies
• Develop and train staff in kiln and comminution process to put in place skills for the future business needs
• Verify that equipment is maintained in the proper original condition
• Verify that equipment is being operated in accordance with the OEM recommendations or as per Plant Manager/HOPExUK recommendations
• The reporting and accuracy of all process related KPI data and other internal reports as required
• The completion of regular kiln and cement line process inspections and the keeping of accurate records at a frequency agreed with the plant manager and head of operational excellence.
• Improving and optimising the process based on the above and other process data
• Providing solutions for operational problems
• Gathering, collating and analysing process and downtime information on kiln line and cement mills and associated equipment
• Monitoring and reporting on the consumption of raw materials, fuel, power, water and air.
• Working with departmental teams to identify and implement efficiencies in the consumption of fuel, power, water and air.
• Writing, maintaining, communicating and training SOPs for the Comminution and Pyro lines and ensure that reviewed on yearly basis.
• Conducting Heat and Mass Balance for Comminution and Pyro lines
• Taking full responsibility to achieve +95% of process optimiser utilisation (Expert system)
• Designing and implementing progressive, costed and planned improvements to the kiln and cement line efficiencies
• Assisting other departments in reaching operational targets
• Sharing best practice with other Heidelberg Materials cement plants on comminution and Pyro operation
• Performing any other process efficiency related duties as reasonably required by line management
• Providing ongoing operational support to the plant for all shifts by participating in the plant’s on call program. This includes evaluating and determining the course of action for incidents after hours and on weekends while on call and may require on-site supervision of the resolution to maintain operational efficiency
• Actively involve during all the Plant shutdowns and support production team to achieve all the tasks including refractories requirement and installation.
• Assessing potential alternative raw material, fuels and additives for improvements to improve the efficiency and cost reductions via trials.
• Support project implementation by taking the process lea