Anthony Mwiinga Kaayunga
Solwezi
Summary
Dynamic chemical engineer with a bachelor's degree in chemical engineering, specializing in energy and combustion engineering, and over sixteen years of extensive experience in mineral processing and metallurgical processes. Expertise includes smelting processes such as ISA furnace operations, matte settling electric furnaces, and waste heat boilers, as well as sulphuric acid production through both single and double contact methods. Proficient in fire refining techniques and casting operations, along with advanced water treatment processes including softening, filtration, and demineralization. Additionally experienced in brash arc furnace operations for titanium slag and pig iron production, and the management of injection refining stations and pig iron casting.
Overview
17
17
years of professional experience
Work History
Production Superintendent Furnaces Hot
Advanced Smelting Industries Cluster
2024.07 - Current
- Take control of furnaces operational performance daily.
- Manage slag and iron chemistry in the furnaces in collaboration with the Technology section.
- Overseeing the compilation of standards and procedures and enforcing these standards in the work place.
- Actively manage continuous improvement within his department through the MOC system.
- Maintain and improve safety, quality and document control standards (ISO 9001, 1400, 18001).
- Assume responsibility in achieving furnace PRODUCTION AND COST TARGETS WITH AN operating budget OF >=r100M/A.
- Manage process failures and ensure speedy recovery thereof.
- Improve and maintain cross-functional customer relationships.
- Conduct troubleshooting in order to identify the root cause for the substandard operating condition.
- Ensure weekly and monthly production data and stock control are done accurately.
- Fulfill standby duties as per schedule including shutdown coordination.
- Manage the raw material requirements and manage stockpiles in collaboration with the Technology and Treatment section.
- Chair meeting: production, quality, safety, non-conformance and incident investigations
Process Coordinator Secondary Smelting
Kansanshi Mine Plc
2023.03 - 2024.07
- Direct and coordinate activities on Secondary smelting side of the smelter comprising of Pierce- Smith Converters main aisle cranes operations; Anode furnaces with their respective casting wheels to achieve maximum copper anode production of good quality to satisfy our customer demands.
- Ensure quality of anodes is maintained and that good quality anodes are dispatched. Critical checks on anodes to satisfy customer demands.
- Ensure all operating parameters for the furnaces are within the limits and any deviations are monitored and corrected.
- Investigate any operations upsets in the operations system and offer solutions.
- Work in liaison with the analytical lab to ensure quality material is delivered and reports for any deviation are reported.
- Ensure lowing and refining of times of both converters and anode furnaces are as minimal as possible to meet and maximize production targets without deviating from normal operating procedures.
- Ensure availability of mobile equipment I the section and any breakdowns reported.
- Ensure efficient use of human resource under my control to effect maximum possible productivity compatible with safety regulations, good labor relations and discipline.
- Facilitate by making equipment available for maintenance by working hand in hand with the maintenance teams.
Process Co-coordinator Primary smelting
Kansanshi Mine Plc
2017.06 - 2023.02
- I was part of the team that ensured that operating parameters are within specified ranges to increase lance life of 32 days of smelting time which is the longest life of a lance for the company. Assisted the control room operators to achieve this.
- Awarded by smelter manager for being safety cautious after I stopped works that was not as per risk assessment despite being behind time in the shutdown which could have led to a fatality.
- Monitors and interpret assay results from process streams and plant process historian system PI
- Provide direction and control to control room and field operators by ensuring process deviations in operating parameters are reported and investigated and remedial actions taken in time.
- Monitor the operations at material handling sections (larox filters, thickener, blending and export sheds, reagent bins)
- Ensure furnace products are within the required ranges and that targets are met and the water quality of the waste heat boiler is maintained within the specified limits.
- Understand and identify all relevant plant requirements, process control and emergency systems and be able to explain to others for process improvements.
- Provide training and development opportunities for all direct reports on an ongoing basis
- Enforce all safety requirements, policies procedures and legal regulations pertaining to safety, health and environment that they are implemented as prescribed.
Process Control and improvement Engineer
Mopani Copper Mine Plc
2016.10 - 2016.12
- Investigated the premature lance failure which resulted in 5.5 day of lance life against a target of 7days, put in corrective measures and lance life improved to above 15 days which in turn reduced the cost of repairs by $70000. The team was awarded for complying and achieving by going above the lance life target.
- Working closely and reviewing operating parameters, refractory life was increased by reducing the wear rate from 0.31mm to 0.2mm per day.
- Monitor, analyze and report on the operation of plant equipment items and processes in the primary Smelting Section using a range of tools and systems.
- Attend all process reviews as necessary and making sure that all agreed recommendations are adhered to.
- Metallurgical control of ISASMELT furnace and MSEF i.e. slag chemistry and matte grade control, MSEF copper loss control, furnace temperature & refractory wear control, lance life control etc.
- Offer technical advice, set operating parameters/ standards and process information to production team and maintenance workers to assist in achieving plant safety and production targets
- Identify process and equipment problems; develop strategies, changes and modifications to solve these problems
- Identify opportunities and manage projects for process improvements, provide technical supervision and assistance during plant shutdowns.
- Develop operating procedures, risk assessments, safe work instructions and other similar documents as required
- Write technical reports and give technical presentations to internal and external audiences
Production controller Smelter
Mopani Copper Mine Plc
2015.12 - 2016.10
- Evaluation of all operating parameters for the isa smelt, electric slag cleaning furnace, waste heat boiler, demineralization plant, Sulphuric acid plant, Pierce smith converters, fire refining anode furnaces, cast wheel and oxygen plant and prescribing corrective measures for any deviation.
- Troubleshooting daily smelter concerns, identifying and implementing overall operational improvements by working hand in hand with the technical team.
- Identify technical and operational problems affecting plant efficiency so as to recommend corrective action and improve plant performance through close process stream monitoring and analysis of assays.
- Increased equipment availability by implementing plant maintenance, follow up on breakdowns to reduce down time and operating them at design specification.
- Maintain the safety of all subordinates by ensuring that all safe operating practices are adhered to and to develop an effective and motivated team of employees in the section and ensure environmental and quality requirements are met according to company policy.
- Ensure efficient use of human resource under my control to effect maximum possible productivity compatible with safety regulations, good labour relations and discipline.
- Ensure availability of all mobile equipment by reporting all breakdowns to the relevant people.
Assistant Superintendent Improved Material Handling
Mopani Copper Mine Plc
2015.06 - 2015.11
- Initiated the idea of stockpiling concentrate in designated areas for ease metallurgical accounting and increase efficiency and less material contamination thereby improving Isa furnace chemistry because of consistent concentrate assay fed to the furnace.
- Stockpile system helped reduce feed conveyor error 7.5% reducing the effect of bad chemistry in smelting process which in turn increased plant availability by 3.8%.
- Stock pile system also helped to increase copper recovery by 10% and maintain good housekeeping around the plant.
- Closely monitored the fine silica quality delivered was as per specification, this help reduce the high consumption of silica saving the company costs.
- Work in liaison with the analytical lab to ensure quality material is delivered and reports for any deviation are reported.
- Stock pile clearance less than 3% error and clearance reports are submitted for each pile cleared.
- Plan for monthly calibrations of all concentrate weigh feeders and reports circulated. Also conduct live load tests.
- Ensure root cause analysis is completed in time for any breakdown in material handling section and reports submitted to superintendents and manager.
- Equipment condition monitoring by ensuring that each shift fills in checklists and report generated and submitted for planning purposes daily.
- Ensure 85% equipment utilization to effect productivity and administers the smelter mobile fleet maintenance in liaison with heavy equipment repairs.
- Ensure health, environmental and safety policies are adhered to.
Production Controller – Primary Smelting
Mopani Copper Plc
2013.01 - 2015.05
- In 2013, I was awarded with a certificate of consistence and good leadership by the manager Metallurgical and for building the team that was highly motivated.
- Maintain high product quality by evaluation of all operating parameters for the Isa smelt, matte settling electric furnace, waste heat boiler, demineralization plant, and acid plant and prescribing corrective measures for any deviations.
- Identify and record operating problems for Isa smelt, matte settling electric furnace, waste heat boiler, demineralization plant and acid plant, and to effect solutions to all operating problems as advised by superintendent primary smelting and acid plant.
- Maintain the safety of all subordinates by ensuring that all safe operating practices are adhered to and to develop an effective team of employees in the section.
- Ensure that the primary smelting plant is online and that production targets for concentrate, reverts and acid are met
- To work hand in hand with maintenance personnel during scheduled maintenance and plant break downs.
- Ensure efficient use of human resource under my control to effect maximum possible productivity compatible with safety regulations, good labour relations and discipline.
- Ensure availability of all mobile equipment by reporting all breakdowns to the relevant people.
- To ensure that all safety, environmental and quality requirements are met according to company policy.
- Maintain liaison with analytical laboratory for the analysis of the samples for the preparations of standard matte for the converters
Foreman Smelting
Mopani Copper Mine Plc
2010.05 - 2012.12
- Ensure timely execution of work and subsequent dispatch of matte to Converters.
- Supervise Isa tapping and matte tapping to converters and slag skimming to slag dam
- Ensure that subordinates observe established safety rules, regulations and procedures during work.
- Supervise the activities of the Control Room and Field Operators for smooth & safe operation of the Plant by close monitoring of the operating parameters and controls the usage of consumables, safety supplies, sundry supplies and office supplies.
- Supervise the operations of the Waste Heat Boiler, Matte settling electric furnace both in the control room and in the field by monitoring the operating parameters and ensure operations are within the set standards.
- Train and develop subordinates on the job and ensure good house-keeping is upheld to the acceptable standards.
- I was part of the team that was awarded for highest production copper anodes for the department and company at large (2010).
Chemical Technologist
Mopani Copper Mine Plc
2008.09 - 2010.04
- Underwent process training and development program:
- Trained as Control room operator- ISASMELT furnace, Waste Heat Boiler(WHB), Matte Settling Electric Furnace(MSEF), Improved Materials Handling(IMH), Sulphuric Acid
- Trained as Foreman - ISASMELT furnace, Matte settling electric furnace, Improved Material Handling, Acid plant, converters and anode furnaces.
- Implemented plant operating parameters for the waste heat boilers, Isa smelt and matte settling furnace as set by the senior process engineers.
- Field operations to ensure efficient use of equipment for smooth running of all plant areas
- Worked with senior process engineers to ensure production targets are met.
Education
Bachelor of Engineering - Chemical Engineering
Copperbelt University
Kitwe Zambia2020-01
Diploma - Chemical Engineering
Copperbelt University
Kitwe, Zambia2008-01
Bachelor of Enginneering - Chemical Engineering
Copperbelt University
Kitwe, Zambia2020-01
Skills
- Process development, process control, optimization, reporting skill and commissioning
- Good leadership, supervisory of production processes and analytical skills
- Good knowledge of Occupational health, Environmental and safety management systems
- Good knowledge of metallurgical product sampling protocols
- I am proficient with computer DCS, Active PI, Microsoft word, excel, power point, and SCADA and SIEMENS operating systems
- Good training, motivation and team building skills
Accomplishments
- Currently heading a water project to optimize usage of process water and avoid waste and focus on utilizing the water in the system. The optimization initiative will save the company from annual costs of 22 million Saudi Riyals.
- Currently running optimization projects with the agenda of reducing costs and improve production. Repairing of injection lance for iron refining, reduction of operational consumables and optimizing production.
- Currently involved in the designing steps and commissioning of the sections of the plant in preparation of the the start up of furnace two brush arc electric furnace for titania and metal production
- Revised standard operating procedures that were initiated four years ago to the ISO 90001 standard.
Affiliations
Member of the Engineering Institute of Zambia as a Professional engineer (EIZ No. 220601130008973)
Languages
English
Full Professional
bemba
Native or Bilingual
Tonga
Native or Bilingual
Nynja
Professional Working
Timeline
Production Superintendent Furnaces Hot
Advanced Smelting Industries Cluster
2024.07 - Current
Process Coordinator Secondary Smelting
Kansanshi Mine Plc
2023.03 - 2024.07
Process Co-coordinator Primary smelting
Kansanshi Mine Plc
2017.06 - 2023.02
Process Control and improvement Engineer
Mopani Copper Mine Plc
2016.10 - 2016.12
Production controller Smelter
Mopani Copper Mine Plc
2015.12 - 2016.10
Assistant Superintendent Improved Material Handling
Mopani Copper Mine Plc
2015.06 - 2015.11
Production Controller – Primary Smelting
Mopani Copper Plc
2013.01 - 2015.05
Foreman Smelting
Mopani Copper Mine Plc
2010.05 - 2012.12
Chemical Technologist
Mopani Copper Mine Plc
2008.09 - 2010.04
Bachelor of Engineering - Chemical Engineering
Copperbelt University
Diploma - Chemical Engineering
Copperbelt University
Bachelor of Enginneering - Chemical Engineering
Copperbelt University