Job Description

Job Summary:

The Plant Process Engineer is responsible for the lime kiln process and associated production units.  Leads the development of processes, procedures, and tools associated with the lime manufacturing process to reduce production cost and improve efficiency while making quality products, respecting emissions limits and putting safety first. Responsible for the continuous improvement and optimization of combustion and calcination as well as optimization of resources.  Performs root cause analysis to determine most appropriate corrective actions.  Actively engages plant management and hourly workforce to ensure alignment with plant maintenance and production departments for execution of the responsibilities of the Plant Process Engineer.  Develops strong interpersonal relationships and constructively works across organizational boundaries to resolve production and process barriers.

• Identify production bottlenecks, develop action plans, and execute them and assess results.
• Conducts daily handoff meetings with operators and team leaders to provide daily instructions for production expectations, identify barriers experienced during shifts, and communicate to others within the operation; attends other meetings as required.
• Provide technical support to production, maintenance, environmental, and quality.
• Monitors reliability of the processes to define paybacks for improvements.
• Perform inspections during major outages of refractory, instrumentation and prepare shutdown reports. 
• Document problems related to the process or systems as seen or received from production.  Reviews results with plant team to initiate, recommend, provide and/or implement solutions.
• Conducts process and energy audits to identify opportunities for cost savings.
• Tracks and performs raw material analysis for the best use of the available fuels and stone conducting cost benefit calculations.
• Monitors stone quality, size and gradation, and fuel quality analysis and their impact in product quality.
• Prepare and maintain Standard Operating Procedures and manuals.
• Trains operational personnel on kilns
• Drive environmental compliance testing.
• Performs other duties as assigned.

Responsibilities:

• Owns operations strategy of the plant, giving direction to production of how to operate the kilns in order to maximize production and minimize cost.
• Owns refractory strategy and budget for the plant and is accountable for its financial performance. Refractory brick management
• Manages the process capabilities of the rotary lime kiln, Grinding Mill, and other material handling systems on site.
• Monitoring, tracking, and continuous improvement of the stone feed system, calcining process, lime quality, and accuracy of all inputs to production, stone, fuels, additives, post-production packaging, etc.
• Building strong relationships with all groups within the site, region and company to ensure seamless communication and productivity.
• Production, operational efficiencies of the kiln process, and oversight of employee capability and productivity in regard to the kiln process.
• Production consistency ensuring product quality and respecting environmental limits.
• Ensuring a safe work environment in the execution of all duties and activities.

Requirements:

• Qualified candidates will have a Bachelor of Science Degree in Chemical Engineering, Minerals Processing Engineering, Mechanical Engineering, or related field.
• 5+ years experience in an Engineering role within maintenance or operations.
• Experience in Root Cause Analysis and troubleshooting.
• Industry background in manufacturing related to mining, paper mills, steel plants, refractory, heavy equipment fabrication, stone processing, cement plants, rotary kilns etc.  Lime and cement experience is preferred.
• Qualified candidates will exhibit a positive and proactive attitude with high initiative and the ability to perform with minimal supervision.
  • Able and willing to spend the majority of time in the plant with the operators, maintenance personnel, and contractors; and able to communicate production and process plans effectively.
  • Able to do limited travel to other sites and regions as needed.
  • Good technical aptitude and analytical skills.
  • Detail and process oriented with strong problem resolution abilities.
  • Excellent communication and interpersonal skills.
  • Must be able to support a continuous improvement environment as well as support change management initiatives.