Lead Smelting Process

Aditya Birla Group -
Madhya Pradesh

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Job details

4 days ago

Qualifications

Research
Project management
Data analytics
Technical writing
Manufacturing
Root cause analysis
Leadership
Communication skills

Full job description

Designation:

Location: India Madhya Pradesh Bargawan, Singrauli

Organization: Metals

Job Description:

1) Job Purpose

The MCOE-Technology has been established as a world-class R&D facility with the primary objective of leading technology design initiatives to support all businesses of Hindalco, addressing both current and future needs.

The role of Lead – Smelting Process is a leadership role within MCOE Technology team and is expected to plan and lead research & development related to aluminium smelting process technologies for sustainable and efficient aluminium smelter operation.

This role requires a blend of scientific expertise, strategic thinking, and operational acumen to drive process efficiencies, implement innovative technologies, and meet environmental sustainability targets in a complex and highly regulated smelting environment.

One of the key objectives of this role is to lead research in the smelting process technology, ensuring continuous improvement in productivity, energy efficiency, and environmental performance while achieving cost savings. This will include:

Lead technology benchmarking of aluminum smelting process performance as well as to focus on reducing GTC emissions, increasing Al?O? enrichment, and managing hazardous waste effectively.
Develop solutions to improve smelting process efficiency and pot lifespan by analyzing preheating and pot start-up practices, bath chemistry & its impacts.
Provide expert technical support in evaluating new smelting technologies or solutions aimed at energy reduction or amperage increase. Facilitate their adaptation while ensuring process stability and managing abnormalities during pilot pot testing.
Establish and oversee smelting lab (400 kA booster pot section) and establish measurement system and regular data analysis of pot performance and SOP development.
Actively invest in self-development by staying updated on the latest advancements, trends, emerging technologies in aluminium smelting and ensure awareness, and dissemination of those knowledge within Hindalco.
Collaborate with all the smelter plants of Hindalco and MCoE functions/department to align with the current and future research need.
Collaborate with ABG business / corporate functions (ABSTC), external vendor/supplier, academic/research institutes (e.g., IITs, JNARDDC, CSIR) to support research and drive innovation in new technology domains.

4) Key Result Areas/Accountabilities:

The role requires seasoned mastery in aluminum smelting technologies with specific emphasis on process optimization, bath chemistry management, and advanced pot operations. This includes deep expertise in raw materials characteristics, data analytics for process control, operational efficiency enhancement, and sustainable practices to reduce environmental impact.

An important aspect of the role is strategic foresight required to formulate technology solutions that not only address current operational challenges but also position the organization at the forefront of industry innovation. This includes staying ahead of emerging trends in primary aluminum manufacturing, alternative technologies, and sustainability practices while ensuring research initiatives align with future market demands and environmental regulations.

An important aspect of the role involves leveraging deep technical expertise to influence and drive consensus among diverse stakeholders - from plant operations leaders and research teams to external partners. The role is required to translate complex technological concepts into compelling business cases, influence enterprise-wide technology adoption, and champion innovative solutions that align with business objectives.

Key Result Areas/Accountabilities

Supporting Actions

Research & Technology Development

Spearhead the booster/pilot pot section for execution / testing of aluminium smelting technology demonstration.
Provide expert level technical guidance / support on the key factors such as raw materials, smelting process operation, bath chemistry management, enhancing efficiency & pot life, lowering emission and waste generation.
Stay updated with the latest advancements, trends, and emerging technologies in the primary aluminum manufacturing and its alternative technology.
Facilitate plant data analysis and provide key insight to improve the aluminium smelter performance.

Exploratory Research

Forecast changes in the industry, technology, and market landscape to identify emerging technology trends.
Conduct in-depth technology scans and brainstorming sessions to identify long-term research needs.
Lead exploratory research in-house and through collaborations with external academic and R&D institutions.

Project Management & Compliance

Plan, execute, and complete R&D projects within the department following established methodologies and quality standards.
Implement procedures to monitor and maintain data integrity, safety, and lab/booster pot section protocols.
Oversee compliance with all regulatory and safety guidelines in the smelting process research.

Team & Resource Management

Develop a strong technical team in smelting technology. Identify skill gaps within the research team and provide necessary training and development opportunities to enhance their capabilities.
Provide leadership to a team of researchers, engineers and technology professionals within the Center of Excellence.
Mentor and develop talent to build a high-performing smelting technology team capable of addressing complex challenges.
Manage the resources effectively to ensure successful project execution.
Provide technical supervision and guidance to the team whenever required in the field.

Collaboration & Networking

Engage with key stakeholders, including global manufacturing leaders, operations teams, and external partners, to align technology initiatives with business goals and drive cross-functional collaboration.
Collaborate with all aluminum smelting plants of Hindalco for energy efficiency, productivity, and sustainability.
Foster partnerships with ABSTC and external institutions, R&D labs to develop innovative technology solutions.
Participate in industry conferences, seminars, and forums to stay ahead in the smelting technology space.

Customer Relationship & Knowledge Management

Develop strategies for regular customer engagement and ensure timely sharing of research progress, findings, and impact reports with stakeholders.
Encourage the team to innovate and generate business-relevant ideas and protect it through patenting those.

Driving Digitalization

Lead digitalization programs for digitalization of core process activities and R&D activities
Facilitate introduction of different digital initiatives to improve and monitor anode quality linking process & raw materials parameters
Interact with plant/ corporate digital team to promote and nurture digital implementation at different possible levels.

Technical Competencies

Essential Technical Competencies

Proven Expertise & knowledge on aluminium smelting process & design technology and extractive metallurgy (non-ferrous).
Deep understanding on emission gas treatment, ALF3 enrichment technology and solid waste management for enhancing sustainability of process.
Strong understanding of the backward integration processes of smelting raw materials, such as alumina and power.
Awareness of potential safety risks associated with booster section lab operation, and ability to implement appropriate risk mitigation strategies.
Proven track record of managing and executing large-scale, complex R&D projects within stipulated timelines and budgets.
Ability to conduct techno-economic assessments of R&D projects and proposed solutions, ensuring alignment with business goals and cost-effectiveness.
Expertise in root cause analysis (RCA) and using data analytics tools for generating key insights from data.
Effective communication skills and team leadership, with experience collaborating with cross-functional and multidisciplinary teams to drive innovation and project success.

Desirable Technical Competencies

Knowledge on carbon anode, alumina production process and technology.
Deep understanding of production systems, process improvement methodologies (e.g., Lean, Six Sigma), and how to integrate engineering innovations into large-scale manufacturing environments.
Strong technical writing skills for patents and publications, along with the ability to deliver clear and impactful presentations.

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Job Description:

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