Shift Lead - Chlor-Alkali, Hydrochloric Acid, Sodium Hypochlorite, Air Compressor at Karwar Plant

Company Overview

Aditya Birla Chemicals operates multiple units across India producing chlor-alkali products. The Karwar facility manufactures phosphoric acid and caustic soda using advanced membrane cell technology, replacing the older mercury cell process for environmental compliance. This plant also produces hydrochloric acid, liquid chlorine, and sodium hypochlorite. The production is energy intensive, with power costs constituting approximately 65% of total manufacturing costs.

Role Purpose and Context

The position involves overseeing production and maintenance activities for the caustic soda plant and value-added products, focusing on optimizing plant effectiveness, managing power consumption, ensuring product quality, and adhering to safety and environmental regulations. The role also entails procurement and market management, taking into account stiff competition and global market influences.

Key Challenges

• Handling of hazardous chemicals such as caustic soda lye, liquid chlorine, hydrochloric acid, chlorine, and hydrogen gas.
• Maintaining critical process parameters to optimize power and chemical consumption while extending equipment life.
• Managing frequent production interruptions caused by grid power failures.
• Ensuring uninterrupted, trouble-free plant operation to minimize breakdowns.
• Applying new technologies for chlorine liquefaction and sodium hypochlorite production.
• Preventing chlorine gas leakage to protect the environment and personnel.
• Compliance with pollution control norms for emissions and waste management.
• Conserving water resources, given the scarcity and costliness at the Karwar site.

Responsibilities

• Execute production processes and maintain operational parameters to achieve targeted quantities and quality for products like liquid chlorine, hydrochloric acid, sodium hypochlorite, and maintain air compressor and cooling systems.
• Monitor daily plant performance and report findings.
• Control consumption of raw materials and utilities to achieve efficiency.
• Communicate management plans effectively for seamless execution.
• Collaborate across departments to ensure smooth plant operations.
• Maintain product quality by adhering to process parameters tailored to customer requirements.
• Optimize chemical usage and reduce losses through process improvements.
• Support maintenance activities to minimize operational losses and downtime.
• Follow standard operating procedures to maximize efficiency and prevent equipment damage.
• Control chemical consumption for downstream products like sodium hypochlorite.
• Proactively identify and resolve operational issues through problem-solving techniques.
• Prepare and manage shift reports and ensure availability of resources for team effectiveness.
• Ensure compliance with safety protocols, environmental standards, and workplace safety certifications (OSHAS 18001, ISO 14001, SA 8000, WCM).
• Lead emergency response for incidents such as chlorine leaks and train teams for safety adherence.
• Maintain customer service standards by addressing internal and external needs promptly and instituting corrective actions when necessary.

Additional Information

The role operates in a complex business environment with multiple products and technologies, under competitive pressures from domestic and international suppliers. Continuous improvements in energy efficiency and process safety are critical to maintaining product quality and meeting environmental norms.