Sakthiselvan Selvaraj

• Collaborate with Production Manager and Plant General Director to enhance overall plant operation and optimisation through process engineering.
• Process and optimisation lead from quarry to packing facility
• Managed quality of limestone and additives, ensuring adherence to quality targets.
• Conducted weekly stock verification and pile formation of limestone and additives.
• Monitored equipment efficiency using key performance indicators (KPIs).
• Reviewed process measurements, initiating necessary operational adjustments.
• Optimised kiln operations through process improvements and raw mix design adjustments.
• Prepared & reviewed refractory management and production budgets.
• Executed shutdown planning and ensured effective implementation.
• Led new cost-reduction projects, achieving SEEC targets funded by KSA government.
• Reduced Specific energy consumption up to 20 % by solving the process related issues

• Oversaw production operations, encompassing raw material handling, pyroprocessing, Raw and cement grinding.
• Directed a team of 70, including engineers, operators, and labourers, ensuring effective management.
• Conducted production planning and supervised daily operations to achieve optimal efficiency.
• Executed shutdown planning while managing implementation to reduce downtime.
• Reviewed process measurements to optimise operations and implement modifications.
• Managed refractory budget preparation in compliance with financial guidelines.
• Performed process calculations, including heat and mass balance for kiln operations.
• Promoted a culture of continuous improvement within the production team leading to higher efficiency levels.
• Collaborated with other department heads to align production goals with business objectives.

• Oversaw operations for Loesche VRM LM46.2+2 and Hot Gas Generator.
• Optimised cement grinding VRM for enhanced performance.
• Conducted periodic inspections of mill and circuit to minimise downtime.
• Performed process calculations for heat, material balance, and grinding efficiency.
• Executed flow and false air calculations to improve system efficiency.
• Managed handling of raw materials including GGBS, wet fly ash, clinker, and gypsum.
• Produced PPC, OPC 43, OPC 53, and PSC grades meeting market quality standards.
• Collaborated with safety team to identify and address plant safety issues.

• Production planning and section head for Kiln, Raw mill and Coal mill
• Manpower management for CCR operation, site activities, and for shutdowns
• Process optimization for Kiln, Raw mill, and coal mill
• Heat balance, combustion calculations, flow calculations, and mills calculations like crash stop sampling, piece weight, separator efficiency, etc.…
• Refractory and grinding media management
• Solving day-to-day operational issues in running the plant
• Establishing new logic and logic modification in PLC for the smooth and safe operation of the plant.
• Housekeeping activities in Pyro-section
• Inter-department function for smooth functioning of the plant.

• Processed calculations for kiln, raw mill, and cement production.
• Managed kiln operations, quantifying and feeding tire chips as alternative fuels.
• Produced various cement types, including SRC, OPC, Oil well Cement Class G HSR grade, White Cement, and GGBS, maintaining quality standards.
• Troubleshot process-related issues, implementing permanent solutions to prevent recurrence.
• Monitored production rates and mill performance to identify areas for improvement.
• Conducted separator efficiency calculations and heat balance assessments through crash stop sampling.
• Guided shift operations focused on process optimisation and efficiency.
• Coordinated interdepartmental efforts to ensure safe and efficient production activities.

· The roles and responsibilities as a Senior Assistant Manager (Process) include:

· Kiln section In-charge for 4 years and looked after cement mills in the absence of cement mill in-charge.

· Heat and Mass balance calculations for Pyro-processing to ensure the optimal energy consumption

· 100% pet coke plant with saw dust, cashew shell and tyre chips as alternative fuel.

· In-charge of alternative fuel from feeding hopper to weigh feeder in smoke chamber.

· Flow calculations, combustion calculation, flame momentum, false air and fan performance etc. for Pyro-section

· Actively lead a safety team to identify unsafe area and to correct it for men, material & machine safety

· Refractory Management

· Continuously monitoring cement grinding unit (ball mill closed circuit) for optimum effectiveness

· Skill Development pillar team coordinator in TPM - Conducted many training programs and trained many individuals from workers to engineers’ level

· Created SOPs for cyclone jam removal, ESP inspection, Mill starting procedures, etc... Worked as a team for power and fuel saving.

· Effectively handled refractory work during shutdowns.

· Handled internal audit and documentation activity for API certification,

· ISO 9001:2015, ISO 14001:2015 and ISO 18001:2007.

• Induction program and classroom training for one month in the plant.
• Department-wise training for 3 months from mining to packing and sales & marketing
• Operation of cement ball mills, raw mill VRM, and Kiln & coal mill for 2 years
• Shift in charge for Pyro-section one year
• Process calculation and process simulation training.

• I worked as a Design Engineer – Process for cement, pharma, and specialty chemicals in IEC Fab Chem Limited, Chennai, India.