AMIT KUMAR GUPTA

It’s a 1.8 million MTPA dual discharge (Hot & Cold DRI) MXCOL MIDREX based DRI Module commissioned
in 2014.I joined JSPL in 2012 in project phase and was actively involved in preparation of SOP’s along with
MIDREX commissioning experts, logic checking / simulation, commissioning and startup of plant.

 Initially served the DRI Technical service department as lead Process Engineer for three years and thereafter managing Operation and Maintenance of DRI Plant as Shift In charge in accordance to department requirements.
 Study and Tracking of process parameters & take corrective action in consultation of Production In charge.
 To bring about improvement in operating practices in accordance with change in gas quality, Raw material without effecting the product quality.
 Training and orientation of new graduate engineers and getting them acclimatized with the process.
 Preparing documents and compliance reports after assisting various internal and external auditors like Factories & Boilers, Engineers India limited, State & central Pollution control board, Renoir consultancy etc.
 Keeping an eye on Raw material & utilities consumption on daily basis and minimizing the specific consumption.
 Finding out bottlenecks of product quality and maintain good quality product and insuring the safety of equipment and men. During breakdowns convey information to subordinate departments and take proper action.
 Making Technical reports for Breakdowns / Shut down compliance and submitting to Plant head.
 To assist Production Manager in setting Production target for the month, keeping an eye on the Physical Stock level of various raw materials, consumables & sometimes based on their expected delivery period.
 To ensure the Safety of the Plant & People working in the plant & to clear the non-conformity when need arises.
 Assist in annual shut down & ensure availability of material/spares well in advance so that there is no delay in the annual plan.

There are two 400 series MIDREX DRI Modules which are dismantled & relocated from M/s Mobily, USA.I was a
an active member of project and commissioning team and thereafter worked as Shift In charge in DRI operations.

 Managing shift activities as Operation Shift In charge.
 To keep a track on key Process parameters & ensure that Modules are operating in a safe manner & at optimum level. Also to ensure that Standard Work Procedures & Work Instructions are being strictly followed by all.
 To make plant rounds & ensure that plant is neat & tidy by proper housekeeping which is a part of everybody’s responsibility which in turn further ensures the availability of Plant as per the commitment to the management.
 To keep a track on various raw materials and utilities like Iron Oxide, Natural Gas, Water, Seal gas, Nitrogen etc. and take suitable action in consultation with production manager in case of any deviation.
 To monitor various specific consumptions per MT of DRI produced, to keep the specific consumptions at the minimum possible level & efforts towards cost reduction.
 To prepare the shutdown job list & to ensure that shut down goes off within the stipulated time frame & without any unexpected eventuality under guidance of seniors.
 Actively participated in Annual Turn arounds and supervised various activities like
 Catalyst Screening segregation & refilling. Measurement of Differential Pressure across the reformer tubes and catalyst top up if required.
 Replacement of Reformer Tubes, refractory repairs of Bustle Plenum, RG Ducts and SG off takes.
 Cleaning and refurbishment of slurry handling systems like Clarifier, Settling Ponds, and Hydro cyclones.
 Inspection of Reduction furnace and carrying out necessary repairs of Feed legs, gunning of refractory, inspection of furnace bed thermo wells, bustle ports.

It’s a 400 series MIDREX Module whose capacity enhancement has been carried out time to time by implementing various new engineering and technological advancements and presently producing more than 0.8 million MTPA.
Field Operation:
• Routine inspection of all the running equipment’s, raw material & product physical inspection.
• Carry out routine pumps change over, Measurement of Shell temperature of Furnace and associated ducts and Tube metal temperature Reformer tubes,
Panel operations
• Underwent Training of Panel operation under supervision of senior panel operators and ensure that Module is operating as per the Daily Operating instructions given by Shift In charge.

There are three 500 TPD rotary kilns with WHRB capable of producing 4 MW power by flue gas.Technological partner was Lurgi, Germany.

Panel Engineer:
 Responsible for smooth operation of DRI Kilns in Shift as Panel Engineer (Rotary Kilns Lurgi, West German technology)
 To adhere to DOI (Daily Operating Instructions) as per the Day’s Production planning.
Assistant Shift In charge:
 To ensure that adequate qualitative staff are available all the time in the shift to tackle the abnormal Plant conditions.