Senior General Manager (Sr. GM) / General Manager (GM) – Coke Oven Operation (Common) Job in Chandrapur at Lloyds Metals & Energy Ltd

Key Responsibilities

1. Overall Coke Oven Operations Management

• Lead end-to-end operations of Coke Oven, CDQ, and By-Product Recovery Units to ensure stable, efficient, and safe functioning.
• Achieve targeted Coke production, quality (CSR, CRI, moisture, ash content), and specific energy consumption parameters.
• Monitor and control charging, pushing, quenching, and heating cycles to ensure balanced battery operation.
• Coordinate operation of Coke Pusher Car, Charging Car, Quenching Car, Transfer Car, and CDQ systems.
• Ensure uniform oven heating, proper pressure balance, and gas flow control to prevent battery deterioration.

2. Process Optimization & Performance Improvement

• Drive optimization of coking time, oven pressure, temperature profile, and battery flue operation for improved yield and quality.
• Monitor key operating parameters through DCS/PLC systems and implement corrective actions.
• Benchmark operational performance against industry best practices and implement improvement measures.
• Coordinate with the Power Plant team for CDQ waste heat recovery utilization.
• Initiate and lead technical studies and process trials for yield and productivity enhancement.

3. By-Product Plant & Gas System Management:

• Oversee gas handling, cleaning, and distribution systems ensuring efficient operation of:
• Gas Cooling & Condensation Units
• Electrostatic Tar Precipitators
• Gas Exhausters, Scrubbers, and Condensate Recovery Systems
• Ensure optimal recovery of by-products (tar, ammonia, benzol, sulphur) with minimal losses.
• Maintain coordination with the Gas Distribution and Energy Management teams for stable plant operation.

4. Safety, Environment & Statutory Compliance:

• Ensure 100% adherence to Safety, Health, and Environmental (SHE) standards in all operational areas.
• Drive implementation of LOTO, PTW, confined space, and hot work permit systems.
• Enforce compliance with Pollution Control Board (PCB) norms and ISO 14001 / ISO 45001 systems.
• Conduct regular safety audits, risk assessments, and incident investigations.
• Promote a zero-incident safety culture through awareness and training programs.

5. Maintenance Coordination & Reliability Assurance:

• Collaborate with Mechanical, Electrical, and Instrumentation teams to ensure high equipment availability.
• Prioritize and plan shutdowns and overhauls in coordination with the Maintenance Heads.
• Ensure timely completion of refractory repair, valve inspection, and gas line maintenance.
• Monitor reliability KPIs and drive RCA and preventive measures for critical failures.

6. Manpower Management & Skill Development:

• Lead and manage a large multi-disciplinary operations team across Battery, CDQ, and By-Product sections.
• Ensure optimal manpower deployment, shift planning, and succession management.
• Conduct and oversee training programs on Coke Oven operation, safety, and best practices.
• Build a performance-oriented team culture focusing on accountability, technical competence, and motivation.

7. Energy Management & Cost Optimization:

• Monitor fuel and power consumption, and optimize specific energy usage per ton of coke.
• Drive heat balance improvement programs, waste heat recovery projects, and CDQ efficiency initiatives.
• Identify and implement cost reduction measures in raw material, maintenance, and operations.
• Collaborate with Energy Management Cell for ISO 50001 compliance and audits.

8. Documentation & Reporting

• Ensure accurate and timely reporting of production, quality, energy, and loss analysis.
• Maintain operational logs, performance dashboards, and daily progress reports.
• Prepare monthly management review reports, highlighting achievements, challenges, and improvement plans.
• Review and approve SOPs, Work Instructions, and Operational Manuals.

9. Cross-Functional Coordination:

• Coordinate with Raw Material Handling, Blast Furnace, Power Plant, and Utilities for smooth process integration.
• Interface with Projects, Maintenance, Safety, and Environment departments for synchronized performance.
• Liaise with corporate planning, energy, and finance teams for reporting and budget alignment.

10. Strategic & Continuous Improvement Initiatives:

• Drive Kaizen, TPM, and Lean Manufacturing initiatives across Coke Oven operations.
• Participate in and lead cross-functional improvement teams for performance enhancement.
• Evaluate and adopt new technologies for emission control, productivity improvement, and digitalization (IoT, predictive analytics).
• Contribute to long-term capacity expansion planning and technology roadmap for the Coke Oven complex.

Key Equipment Exposure:

• Coke Oven Battery and Machinery (Pusher, Charging, Quenching, Transfer Cars)
• CDQ Chambers, Cooling Fans, and Waste Heat Boilers
• By-Product Plant: Condensers, Scrubbers, Gas Exhausters, and Compressors
• Gas Cleaning, Tar Separation, and Ammonia Recovery Units
• Hydraulic and Pneumatic Systems
• Gas Distribution and Safety Interlock Systems

Qualifications:

• B.E. / B.Tech in Metallurgical / Mechanical / Chemical Engineering from a recognized university.
• Additional qualifications such as MBA (Operations / Industrial Management) preferred.

Experience:

• Sr. GM: Minimum 25–30 years of experience in Coke Oven operations in an Integrated Steel Plant.
• GM: Minimum 20–25 years of relevant experience with proven leadership in operations, CDQ, and by-product management.
• Experience in commissioning, stabilization, and performance optimization of modern Coke Oven plants (≥0.5 MTPA capacity) essential.

Technical Skills:

• In-depth understanding of Coke Oven battery design, coking process, flue heating systems, and CDQ operation.
• Expertise in By-Product Plant processes and gas handling systems.
• Knowledge of automation (PLC/DCS systems) and SCADA monitoring.
• Proficiency in data-driven decision-making, root cause analysis, and process control optimization.
• Familiarity with SAP PM/MM, MS Office, and plant MIS systems

From commissioning one of the oldest DRI plants in Maharashtra, to pioneering iron ore production in the state while uplifting the places we operate in. Growth which has become synonymous with our performance.
Growth which reflects in our ambitious plans of becoming a world class steel producer. Growth which is not only for us but for the nation at large.