LIJITH GOPALAKRISHNA PILLAI
Queens Park,Australia
Summary
Plant Operations Optimization: Over 14 years of rich experience in chemical engineering, specializing in optimizing operational efficiency within acid regeneration, ilmenite ore beneficiation, chlorination, oxidation and pigment finishing plant of Kerala Minerals and Metals Ltd, and zinc concentrate leaching and purification plant operations of Binani Zinc Ltd. Maintenance/operation Expertise: Proven hands-on capability in annual shutdown maintenance of Synthetic Rutile plant and Acid Regeneration Plant, encompassing the meticulous care/operation of essential equipment such as high temperature Rotary Kilns, Belt Conveyors, Bucket Elevators, Rotary Globe Digesters, Acid Heaters, Spray Roasters, Absorbers for HCl absorption, Cyclone Separators, Fluidized Bed Chlorinators, Heat Exchangers, Tickle Preheaters, Oxygen Preheaters, Chlorine Compressors, and the precise management of the mixing and preparation of batches for various titanium dioxide grades. This ensures seamless plant functionality and contributes to the longevity of the entire system. DCS Proficiency: Proficient in Distributed Control System (DCS) operation, particularly with Yokogawa Centum VS, for precise process control and monitoring. Project Leadership: Successful track record of leading cross-functional teams, delivering Synthetic Rutile Plant commissioning projects on time and within budget. Multi-Tasking and Quality Maintenance: Exceptional multitasking skills in plant operation, equipment maintenance, troubleshooting, optimization, and quality maintenance. Effective Planning and Execution: Demonstrated professional excellence in planning, scheduling, monitoring, and executing operations and managing shifts without time or cost overruns.
Overview
15
15
years of professional experience
Work History
Deputy Plant Manager-Acid Regeneration Plant
The Kerala Minerals & Metals Ltd
05.2022 - 10.2023
- The Acid Regeneration Plant operates with dual intake streams, each capable of processing 12.5 cubic meters per hour of spent liquor from the Ilmenite Beneficiation Plant, resulting in the production of concentrated Hydrochloric acid at a concentration level of 18.5% to 19.5%
- Collaborate with department heads and senior management to devise and execute effective operational strategies and production targets
- Contribute to budget development and adeptly manage expenditures within established limits
- Ensure strict adherence to safety regulations, environmental standards, and legal requirements
- Exercise vigilant control over operational costs, bolstering profitability
- Provide visionary leadership to plant staff, including supervisors and operators
- Dedicate efforts to ensure well-trained, motivated, and highly effective teams
- Enforce proactive maintenance programs, enhancing equipment reliability
- Collaborate closely with production and planning teams to establish production schedules and meet customer demand and monitor production schedules to guarantee on-time delivery
- Proficiently address and resolve quality issues and deviations from standards
- Devise and manage emergency response plans, ensuring thorough personnel training for emergency situations
- Prepare comprehensive reports for senior management and regulatory entities as required
- Foster a culture of innovation and improvement among plant personnel
- Maintain amicable relations with stakeholders, encompassing employees, suppliers, and regulatory bodies.
Deputy Plant Manager-Ilmenite Beneficiation Plant
The Kerala Minerals & Metals Ltd
05.2018 - 05.2022
- The Ilmenite Beneficiation Plant, with a nameplate capacity of 55,000 metric tons per year, plays a pivotal role in the production of high-quality Synthetic Rutile from raw ilmenite
- Oversee and manage the day-to-day operations of the plant, ensuring that production targets are met and quality standards are maintained
- Collaborate with the Plant Manager and other department heads to develop and implement operational strategies and production targets
- Ensure that all operations comply with safety regulations, environmental standards, and legal requirements
- Identify opportunities for process improvements, cost reductions, and efficiency enhancements
- Assist in the development of the plant's budget and work to manage expenses within defined limits
- Monitor and control operational costs to maximize profitability
- Provide leadership and direction to plant staff, including supervisors and operators
- Collaborate with the production and planning teams to schedule production runs and meet customer demand
- Monitor production schedules to ensure on-time delivery
- Implement quality control processes to maintain product quality and consistency
- Address and resolve any quality issues or deviations from standards
- Manage environmental initiatives and ensure compliance with environmental regulations
- Develop and oversee emergency response plans and ensure that all plant personnel are adequately trained for emergency situations
- Prepare reports for senior management and regulatory agencies as needed
- Maintain positive relations with stakeholders, including employees, suppliers, and regulatory agencies
- Address any concerns or issues that arise.
Process Engineer/ DCS Control Room Engineer
Ilmenite Beneficiation Plant, U200 Chlorination plant, U300 Oxidation plant and U400 Pigment finishing plant
10.2009 - 05.2018
- Develop and implement a systematic plan to review the plant's condition at the start of each shift, including inspection of controls and process parameters to ensure product quality and consistency
- Streamline the management of engineering spares, consumables, fuels, and other resources to maintain their availability and support production targets
- Proficient in the operation and maintenance of Rotary Kilns, Furnace oil /LPG/LNG firing system, Belt Conveyors, Bucket Elevators, Rotary Globe Digesters, Acid Heaters, Clarifier, Spray Roasters, Absorbers for HCl absorption, Cyclone Separators, hydro-cyclones, Fluidized Bed Chlorinators, Heat Exchangers, Tickle Preheaters, Oxygen Preheaters, Chlorine Compressors ensuring optimal performance and efficiency in industrial processes
- Proficient in overseeing the mixing and preparation of different grades of titanium dioxide, demonstrating versatility in handling diverse materials
- Identify potential hazards within the plant and make recommendations for necessary rectifications to enhance workplace safety
- Actively participate in quarterly trip drills to enhance operators' ability to respond quickly to emergencies
- Organize and conduct various training sessions for the team to enhance their performance in emergency situations
- Champion the concept of continuous improvement, focusing on enhancing work practices, procedures, standards, and machine performance
- Implement better process control and work discipline to achieve substantial savings in electrical energy and water consumption, contributing to cost efficiency
- Guide, motivate, and supervise a team in conducting troubleshooting and modifications for smooth and safe plant operations, ultimately leading to cost savings
- Redesign and optimize batch processing methods through time studies to reduce processing time for product batches
- Operate the Yokogawa Centum Distributed Control System, overseeing the control of process parameters, scheduled start-up, shut-down, and emergency shut-down activities
- Lead efforts to implement modifications aimed at reducing equipment breakdowns and ensuring operational reliability
- Systematically prepare day-to-day progress reports, manage pre-commissioning activities, hydro testing, test runs, modifications, and troubleshooting documentation.
Project/Operations
Ilmenite Beneficiation Plant
02.2010 - 06.2012
- Successfully oversaw the erection, commissioning, and capacity augmentation of the Synthetic Rutile Plant, ensuring safety and quality compliance and increasing its production capacity from 35,000 MT/year to 55,000 MT/year
- Actively led the implementation of the Distributed Control System (DCS) in the existing plant, significantly enhancing process control and operational efficiency
- Prioritized safety measures throughout project activities, ensuring the well-being of team members and compliance with safety regulations
- Developed and adhered to project timelines and budgets, tracking progress and ensuring that projects were completed within defined constraints
- Facilitated clear communication and collaboration among project stakeholders, including internal teams, contractors, and management, to maintain project alignment and transparency
- Maintained accurate project documentation, including plans, reports, and records of project activities
- Addressed and resolved any project-related issues, challenges, or deviations that arose during the execution phase
- Identified areas for process optimization and efficiency improvements within the project scope, seeking opportunities for cost savings and enhanced productivity.
Process Engineer/DCS Control Room Engineer
Binani Zinc Ltd
02.2009 - 10.2009
- Assumed responsibility for ensuring total compliance with defined operational parameters/ standard Operating procedures to achieve optimum productivity levels in the Leaching and purification plant
- Hand own for operating distributed control system to control process parameters, scheduled start up, shut down and emergency shut down activities
- Successfully bagged the opportunity of maintaining of all records, log book and reading of all work carried out in a shift.
Education
Master of Business Administration - Operations management
IGNOU
B Tech - Chemical Engineering
Anna University (India)
Chemical Engineering
Board of Technical Education
IndiaDiploma - Industrial Safety
Annamalai university
Skills
- Chemical engineering
- Process control
- Distributed Control System(DCS)
- HAZOP study
- Problem solving
- Analytical skills
- Leadership
- Data processing
- QAPC
- Staff Oversight
- Meetings and Presentations
Accomplishments
Steam Consumption Reduction and Process Optimization:
- Achieved a remarkable 0.5 MT/batch reduction in steam consumption during digester batch operations, leading to enhanced productivity and cost savings.
- Extended the replacement schedule of jet channel closing bricks from 152 to 250 batches, improving production efficiency.
Process Delays Minimization:
- Identified and minimized digester batch processing delays by optimizing mixed acid preparation and acid heater lines, resulting in a remarkable monthly batch processing delay time reduction of 150 hours (equivalent to 180 metric tons of product-Synthetic rutile).
- Implemented effective modifications in blowdown tank pumping out lines and logic, reducing monthly batch processing delay time by 110 hours (equivalent to 130 metric tons of product-Synthetic rutile).
- Enhanced efficiency by controlling steam inlet to the digester and making logic modifications, reducing monthly batch processing delay time by 150 hours (equivalent to 180 metric tons of product-Synthetic rutile).
- Optimized wash water blowdown tank pumping out lines and logic, resulting in a monthly batch processing delay time reduction of 22 hours (equivalent to 30 metric tons of product-Synthetic rutile).
Project Commissioning and Cost Reduction:
- Successfully led and contributed to the commissioning of the Synthetic Rutile project at M/s, KMML, Kerala.
- Spearheaded projects worth 32 crore Indian rupees in 2011, which optimized production processes, including the erection and commissioning of rotary kilns, conveyer systems, and storage tanks, resulting in a significant increase in productivity.
Additional Information
Educational qualifications and skilled employment assessed by Engineers Australia (ANZSCO Code-233111)., Australian Permanent Resident
Timeline
Deputy Plant Manager-Acid Regeneration Plant
The Kerala Minerals & Metals Ltd
05.2022 - 10.2023
Deputy Plant Manager-Ilmenite Beneficiation Plant
The Kerala Minerals & Metals Ltd
05.2018 - 05.2022
Project/Operations
Ilmenite Beneficiation Plant
02.2010 - 06.2012
Process Engineer/ DCS Control Room Engineer
Ilmenite Beneficiation Plant, U200 Chlorination plant, U300 Oxidation plant and U400 Pigment finishing plant
10.2009 - 05.2018
Process Engineer/DCS Control Room Engineer
Binani Zinc Ltd
02.2009 - 10.2009
Master of Business Administration - Operations management
IGNOU
B Tech - Chemical Engineering
Anna University (India)
Chemical Engineering
Board of Technical Education
Diploma - Industrial Safety
Annamalai university
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