Shri Mahavir Ferro Alloys Private Limited (SMFA) started its operations in 2003-04 with a 100 TPD sponge iron kiln at the Kalunga Industrial Estate in Odisha. The company further expanded the capacities of its sponge iron plant with the addition of a third 100 TPD Kiln along with two 12 Ton induction furnaces with a Continuous Casting Machine (for Billet casting) in the year 2008. Adding one more feather to its expansion program, SMFA commissioned a 12 MW coal-based Captive Power Plant in March 2008 to meet the power requirements of its three 100 TPD sponge iron plants and steel melting shop (SMS).

SMFA has its railway siding, which was approved by the South eastern Railways in the year 2007, and its design and engineering got approved in 2009. The company upgraded the railway siding to a private freight terminal to cater to plants’ requirements and get the benefit from railway policies along with the added business opportunities with the various manufacturing plants in the vicinity. In 2011-12, SMFA ventured into producing power using renewable sources by commissioning a 1 MW solar power plant under the Jawaharlal Nehru National Solar Mission at Tankajoda village in Sundargarh district of Odisha.

Responsible for overseeing process parameters and consequently product quality of the DRI plant

- Ensure Kiln campaign life improvement
- Ensure optimal steam flow to Waste Heat Recovery Boiler (WHRB) for power generation
- Ensure Sponge Iron yield is greater than target value
- Run improvement projects to enhance yield /reduce cost/reduce accretion
- Monitoring & control of kiln zone wise temperature
- Monitoring & control of RM parameters for accretion control:

• Tumbler index of Iron ore feed
• Caking index of Coal feed
• Ash fusion temp. of coal
• -5mm % of fines in iron ore feed.

- Ensure produced Sponge Iron meets the specifications of the internal customer

- Monitoring of actual cost v/s budget

- Defines the objectives of lab team and carries out their performance reviews, promotes the quality of the work and motivates his/her personnel
- Provide technical / business training hours for DRI team where needed
- Ensure no production loss due to lack of skill in manpower for setting process parameters

- Ensure zero safety incidents & lost time injury in DRI plant
- Ensure compliance for ISO certification
- Promote & monitor 5S in all areas of the DRI plant

- Daily / monthly production plan vs actual achieved

- Ensure flue gas supply to WHRB as per business plan / service level agreement

- Adherence to schedule and planning for the accretion cutting exercise
- Adherence to kiln Shutdown plans and optimize the shutdown duration year-on -year

- Quantity of the sponge iron rejected in the process
- Maintain quality parameters of Plant and Sponge iron (Eg: Fe(M) etc)

- Drive teams to perform root cause analysis for process / quality deviations
- Complete RCAs within 2 days
- Compliance to CAPA action points as per defined timelines

- Coal and iron consumption per ton of the product less than target
- Power consumption per ton of product
- Drive cost optimization projects

- Zero lost time injuries / accidents
- Compliance to EHS and other legal standards
- Train / coach team members on EHS

- 100% adherence to ISO / IMS standards
- Zero NCs in external audits
- Implement best practices
- Train / coach team members on ISO / IMS / SOPs / HIRA / Aspect-Impact

- Work experience as Process Lead of DRI plant with Rotary Kiln process >100 TPH
- B.E – Metallurgical / Mechanical

- Min. 8 years of relevant experience required