Chemical Engineering Plant
Resume:
PROFILE
Process Metallurgist in possession of a qualification in Chemical Engineering with over 5 years’ combined experience in Heavy Industry, Production and Metallurgy.
I have experience in DC Arc Furnaces, Submerged Arc Furnaces, Data Mining & Visualization, Machine Learning, Raw Materials Systems, Effluent Treatment Plants, Crushing and Screening Plants, and Logistics & Export Operations.
EXPERIENCE
SAMANCOR CHROME
MIDDELBURG, MP
JUNIOR METALLURGIST
+3 years’ experience
AREAS OF EXPERIENCE:
Submerged Arc Furnaces:
Process optimization and metallurgical management of the furnaces.
Plant Projects and Trial leading and commissioning.
Furnace Refractory Management: Supervision of Furnace Refractory changes and sacrificial mickey changes, as well as coordination of Furnace Maintenance Shutdowns.
Furnace data analysing, data visualization and data mining on Orange.
Introduction to Python and machine learning.
Process monitoring through Aspen Trends, MES and SCADA.
Monitoring the Furnaces’ Critical Plant Indicators and KPIs.
Updating the Mass and Energy Balance, and Carbon Excess Principles.
Safe operation of the 52 MVA Submerged Arc Ferrochrome Furnaces.
Raw Material Systems’ management and Reductant conductivity tests.
Furnace Electrode Management, and Electrode slipping theories.
Ferrochrome Thermodynamics and recovery efficiency measures.
Analyzing ore quality and its impact on operations.
Accident reporting and compiling of MOCs on IMS.
Plant Inspections: Furnace Building (Roof, Tapping Floors and Casting Bays) and Furnace Raw Material Systems.
Project Involvement:
Intocast Envirotap FA Tap-hole clay and HS restoration clay at M1M2: Trialing environmentally friendly tap-hole clays at both furnaces as a cost saving drive for the plant and company.
Calculation of ladle sculling rate and heat losses when using a ladle lid vs when not using the ladle lid: Introducing the use of a ladle lid to assist in minimizing heat losses on the ladles; the aim of the project is to cut the costs of Sasol Gas used on gas burners for heating up the ladles.
Trial the use of a Slag Detection System to minimize the alloy losses into the slag pot: Introduction of a SDS into the tapping process to minimize alloy carryover and loses into the slag pot; reducing metal recovery costs.
DC Arc Furnaces:
Process optimization and metallurgical management of the furnaces.
Furnace Refractory Management: Supervision of Furnace Refractory changes and DC Arc Ferrochrome Furnace rebuild, as well as coordination of Furnace Maintenance Shutdowns.
Plant Projects and Trial leading and commissioning.
Conducting Senior Production Standby duties.
Safe operation and process optimization of the Howden Scrubber Gas Plant and the Theisen Disintegrator Gas Plant.
Safe operation of the 60 MW and 70 MW DC Arc Ferrochrome Furnaces.
Approval of Production, Material and Electricity consumption tickets.
Monitoring the Furnaces’ Critical Plant Indicators and KPIs.
Update the Furnaces’ metallurgical conditions using FACTSAGE.
Process monitoring through Aspen Trends, SCADA and MES.
Accident reporting and compiling of MOCs on IMS.
Effluent Treatment Plants:
Daily management of the Clarifiers and Cooling Towers.
Daily management of the effluent Filter Press, and optimization of the Bench Filter Press to minimize leakage and improve water quality.
Daily management of Clarifier feeder sump and sump pumps.
Effluent Treatment Plants’ monitoring through Critical Plant Indicators and identify issues that may cause process delays and that require immediate attention.
Raw Materials Systems:
Dust Agglomeration Plant Project: Agglomeration of dust from the Rotary Drum Coal Dryer.
Daily management and inspection of the Raw Material storage bunkers to manage material contaminations in order to take preventive measures and make recipe changes in case of material contamination.
Daily management of the two Chromite Ore fluidized bed baghouse dryers by adjusting the Ore Dryers set points on SCADA to achieve optimum performance from both dryers.
Daily management of batching plant to manage material contamination and take measures to prevent any upset conditions in the furnace and metallurgical instabilities.
Daily management of the Reductant Dryer by adjusting process parameters on SCADA in order to increase the Dryers throughput and optimize the dyer’s performance.
Project Involvement:
Dust Agglomeration Project: Agglomeration of coal dust from a Rotary Drum Coal Dryer.
The investigation is to find means to minimize the dust fallout from the Reductant Dryer Operation. The agglomeration is done inside a shaft-less screw conveyor using HydroTac, a lignin based surfactant, as a binder. The dust pellets that are formed inside the screw conveyor are then transferred onto a conveyor belt and loaded into the raw materials’ storage bunkers; this also reduces the amount of dust generated at the storage bunkers during and after the dryer operation.
This project has a positive impact on the environment as it reduces the amount of air pollution within the plant and surrounding living settlements.
The project was presented at the Samancor Chrome Continuous Improvement Forum.
SAMANCOR CHROME
MIDDELBURG, MP
PROCESS AND EXPORT OPERATOR
2 years’ experience
AREAS OF EXPERIENCE:
Crushing and Screening Plant:
• Start-up and safe operation of the Crusher and Chips Plant.
• Inspection of Crusher and Chips Plant: Screens, Conveyors Belts, Guards.
• Sampling of Plasma and CHCR 10x25 chips, 4x12 chips & fines.
• Off-loading of Plasma and CHCR chips onto the tractors.
• Logging of samples at the Metallurgy Laboratory.
• Inspection of Final Product Stockpiles.
• Training of new Production Operators.
Logistics & Export Plant:
Safe operation of the weighbridges during weighing of internal and external vehicles.
Inspection of road and railway trucks (by taking photos) on the weighbridge.
Completion of offloading / loading documentation; for example: Waybills for road trucks, completing Load Monitoring Document and control of loading documentation.
Health and Safety Representative.
EDUCATION
UNIVERSITY OF SOUTH AFRICA
ADVANCED DIPLOMA IN CHEMICAL ENGINEERING (NQF 7)
IN PROGRESS
• APPLIED CHEMICAL PRINCIPLES
• CHEMICAL ENGINEERING COMPUTATIONS II
• ENGINEERING MANAGEMENT II
• MATHEMATICS III (ENGINEERING)
• CHEMICAL PROCESS DESIGN PRINCIPLES
• PROCESS DESIGN PROJECT
• ADVANCED PROCESS CONTROL
• ADVANCED REACTION ENGINEERING
• SEPARATION PRINCIPLES IIB
• APPLIED THERMODYNAMICS
• TRANSPORT PHENOMENA II
• CHEMICAL ENGINEERING PRACTICALS III
MANGOSUTHU UNIVERSITY OF TECHNOLOGY
NATIONAL DIPLOMA: ENGINEERING: CHEMICAL (NQF 6)
YEAR COMPLETED: 2016
PROCESS CONTROL III
CHEMICAL ENGINEERING TECHNOLOGY III
PRINCIPLES OF CHEMICAL ENGINEERING DESIGN III
CHEMICAL PLANT III
APPLIED THERMODYNAMICS III
CHEMICAL ENGINEERING THERMODYNAMICS III
MATHEMATICS II
PROCESS CONTROL II
Major accomplishments:
Student Residence House Committee Member: Sports Officer.
SKILLS
ORANGE & Python
SCADA
SAP
ChemCAD
Microsoft Excel
ASPEN
Microsoft PowerPoint
Integrated Management System
FactSage
Manufacturing Execution System
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