Muhammad Ahmad

My work experience covers the following process areas:

Technical Support Engineer
Following Principal Companies
• Magotteaux (Ball Mill Upgrades)
• RHI-AG (Refractories)
• CTP (SWAP New Tech-Fiber Filters)

Ball Mills

To perform field visit and to carry out inspection and measurements of ball mill internals, cyclones performance, classifier performance (Tromp curve), Gas flow rate calculations and operational parameters. Involved in installation of new technology Opti Control (Scoop System) diaphragms at Ball Mill and New Technology classifier (Xp4) provided by Magotteaux at ATTOCK CEMENT LIMITED, PK and its process commissioning.
To carry field visits along with supervisors of principal companies to provide technical help and perform field measurements at cement plants of Pakistan. Participating in Cement Mill (Ball Mill) up-gradation at Thatta Cement Limited, PK.

Fiber Filters (Bag Filters)

Recently participated (Successfully Complete) in CTP project (Conversion of 4 Electrostatic Precipitator in to Sonic Wave Acceleration Pulse Fiber Filters) at Power cement limited, Pakistan. Mechanical erection and fabrication supervision and process commissioning. Gas Flow rate calculations (measurements using Pitot Tube) of Fiber Filters, Differential Pressure calculations and process troubleshooting. Process optimization to solve the flowrate problems of Fiber Filters at Power Cement Limited, PK.
To study and collect relevant field data regarding abnormalities in rotary kiln process and the grinding unit i.e. Vertical mills, Ball mills and Bag Filters.
Flowrate measurements at Bestway Cement Chakwal and Bestway Farooqia.

Area In Charge Finish Mills (Ball Mills)

Monitoring & ensuring plant productivity of Ball Mill l & ll. To achieve operational parameter in production targets. To optimize both cement mills for maximum production and to minimize power consumption. To look after M.I.S section and verify all reports before releasing. To look after ERP manufacturing orders, validation of initial data logging and subsequent MIS analysis. To maintain grinding media & grinding aid stock & status. To provide trainings to engineers, operators and technical persons from time to time.

In Charge ERP & MIS Section (Production)
Customization of ERP for production department and its implementation. Also responsible to train all production staff about BOM making, material transactions and inventory supervision, manufacturing orders and their validation. Daily, weekly and monthly plant reports, cost analysis, maintaining inventory, preparation of comparative statements and root cause analysis reports.



Project Engineer including \[worked in plant up-gradation with (Installation of Precalciner), responsible for installation of refractory inside precalciner as per drawing provided by FLS (Germany), responsible for work planning in coordination with mechanical project team, castable filling inside cyclones, precalciner, tertiary air duck and kiln hood. Responsible for all refractory and castable work during project and calculation of bricks per ring and to maintain the daily project progress report\]. Commissioning of plant and successfully putting this to operation.

Raw Mill Area including \[Have been observing mill operation deeply to solve residue problems at Loesche mill LM32.4. Inspection and maintenance of following equipment as per requirement belt conveyors, hard facing of grinding table and rollers of loesche mill, bucket elevator, weigh feeder calibration, centrifugal fans and blowers, lubrication pumps, dam ring adjustment to control material rejection from mill. \]

Coal Mill Area coal handling, maintain coal residue, inspection and hard facing of vertical coal mill rollers and grinding table. To maintain oxygen level inside closed circuit. Drag chain and weigh feeder, belt conveyors calibration and their alignment.

Other than general production work, some of the specific assignments included

• Studied and observed the behavior of vertical coal mill to solve grinding problems and made suggestion to replace nitrogen accumulators and to adjust the rollers which successfully solved the problem and federate was increased.
• Responsible for maintenance work during shutdowns.


Kiln Area including \[Kiln shell inspection during shutdown for refractory replacement, replacement of shell piece in case of shell deformation, inspection of grate IKN cooler and its cooling fans, damper calibration, castable filling inside cooler and cyclones. Inspection and static balancing of kiln induced draft fan. Calculations for material filling degree, material residence time and air required for combustion and cooling. Inspection and calibration of pressure transmitters, temperature sensors and RTD’s\]

Other than general production work, some of the specific assignments included
• To inspect all the equipment for tracing mechanical and electrical problems related to induced draft fan and its static balancing, thermocouples, pressure transmitters, RTD’s, dampers calibrations, dip tube plates of cyclones and its maintenance, calibration of weigh feeders and to calculate the percentage error in physical feed and its calibration by doing drop test for 24 hours.
• Calculation of refractory bricks being installed per ring and to meet the specific diameter of kiln shell.
• Have been guiding control rooms operators how to reduce fuel consumption using operational perimeters also by suggesting minor changes in raw mill chemistry.
• Responsible for kiln refractory lining and castable filling at grate cooler, cyclones during shutdown.
• Responsible for maintaining clinker liter weight, and to solve draft problems of the process.

RDF Project

• Commissioning of alternate fuel system at precalciner (Thatta Cement). Observed and studied the problems caused by using Rice Husk, dry sludge and Rubber e.g. precalciner chocking and CO emission and change in clinker composition.

Internship of 2 months followed by the detailed report submission on Plant equipment with their specifications and production capacities.