Senior Process Engineer

4 weeks ago

Mold, United Kingdom Heidelberg Materials Full time

Heidelberg Materials UK (formerly Hanson UK) is one of the UK's largest suppliers of construction materials, employing over 3,500 people and operating around 280 manufacturing sites in the UK.

We are committed to building a more sustainable future and recognise that a diverse workforce is key to our growth and development. We aim to foster a culture that values openness, transparency and individual achievement.
The role holder is responsible for: Monitor and optimize the kiln and cement lines, from raw materials to finished product. Improve the operating efficiency of the pyro, comminution and associated equipment - to include reduction of air usage and false air, reduction of electricity and fuels, increasing alternative fuels, increasing alternative raw material consumption, reduction of water usage. Report to management team on performance against KPIs and other key metrics. Set process-related targets for operational staff. Design and implement progressive, costed and planned improvements to the mills and kiln efficiencies; to include mill and kiln inspections and associated studies. Develop and train staff in kiln and comminution process to put in place skills for the future business needs. Verify that equipment is maintained in the proper original condition. Verify that equipment is being operated in accordance with the OEM recommendations or as per Plant Manager/HOPExUK recommendations. The reporting and accuracy of all process-related KPI data and other internal reports as required. The completion of regular kiln and cement line process inspections and the keeping of accurate records at a frequency agreed with the plant manager and head of operational excellence. Improving and optimising the process based on the above and other process data. Providing solutions for operational problems. Gathering, collating and analysing process and downtime information on kiln line and cement mills and associated equipment. Monitoring and reporting on the consumption of raw materials, fuel, power, water and air. Working with departmental teams to identify and implement efficiencies in the consumption of fuel, power, water and air. Writing, maintaining, communicating and training SOPs for the Comminution and Pyro lines and ensure that reviewed on yearly basis. Conducting Heat and Mass Balance for Comminution and Pyro lines. Taking full responsibility to achieve +95% of process optimiser utilisation (Expert system). Designing and implementing progressive, costed and planned improvements to the kiln and cement line efficiencies. Assisting other departments in reaching operational targets. Sharing best practice with other Heidelberg Materials cement plants on comminution and Pyro operation. Performing any other process efficiency related duties as reasonably required by line management. Providing ongoing operational support to the plant for all shifts by participating in the plant's on-call program. This includes evaluating and determining the course of action for incidents after hours and on weekends while on call and may require on-site supervision of the resolution to maintain operational efficiency. Actively involve during all the Plant shutdowns and support production team to achieve all the tasks including refractories requirement and installation. Assessing potential alternative raw materials, fuels and additives for improvements to improve the efficiency and cost reductions via trials. Support project implementation by taking the process lead. What's on Offer: Salary: Competitive Salary
Location: Padeswood
Hours: 40
• Employer of choice: Armed Forces Covenant (Silver) / Disability Confident Committed / 5% Club (Platinum) / Mates in Mind / Clear Assured (Foundation) / The Mineral Products and Qualification Council (MPQC) / STEM Ambassador
• Compensation Package: Bonus incentives / Generous Pension Schemes / Life Assurance
• Work Life Balance: 27 days holiday (excluding bank holidays) / Agile working / Flexible working / Holiday purchase / Sabbatical
• Family Friendly: Enhanced policies such as Maternity / Paternity / Parental Leave / Neonatal / Adoption/IVF/Menopause
• Social Value: paid Volunteering Day every year / Communities (LGBTQ+, Network of Woman, Woman in Science and Engineering (STEM), Armed Forces)
• Wellbeing: Employee Assistance Programme (EAP) / Mental Health First Aiders / Cycle to Work / Employee Benefits portal including Gym discount / Free eye tests / Discounted Private Medical cover
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