Plant Operations Specialist

Position-GM Plant
Location Ambaji (Gujrat)
Assignments:
A. Plant Commissioning & Strategic Leadership
Lead the beneficiation plant from construction/pre-commissioning through commissioning and ramp-up to peak capacity, coordinating closely with EPC contractors, equipment OEMs and the Project Director.
Oversee day-to-day plant operations to ensure production targets are met; develop production plans and schedules aligned to mine ore supply and project/customer requirements.
Implement and maintain standard operating procedures (SOPs) for all plant activities; analyse production data and drive continuous improvement in productivity and cost-effectiveness.
Address quality or throughput issues and implement corrective actions as needed; coordinate across mining, maintenance, QC and logistics for smooth material flow.
Lead preparation of the Techno-Economic Feasibility Report (TEFR) and Detailed Project Report (DPR) for the beneficiation plant, and prepare tender documentation and finalise contracts with EPC contractors, technology licensors and equipment suppliers for plant construction and major capital projects.
B. Process Technology, Engineering & Metallurgical Performance
Lead process technology and major equipment selection in coordination with technology licensors and OEMs, and own development of Process Flow Diagrams (PFDs), expediting detailed engineering with EPC/engineering consultants.
Drive process control and metallurgical optimisation of grinding and selective/differential flotation circuits to maximise recovery of copper along with lead and zinc, against design/target recovery rates, across varying ore sources and grades.
Own metal and mass balance reconciliation for the plant, and track cost of production (including manufacturing input cost) against budget.
Drive plant upgradation through introduction of instrumentation and PLC-based process control to improve consistency and reduce manual intervention.
C. Mechanical Operations & Maintenance
Lead and supervise the mechanical team in executing daily plant operations, ensuring compliance with safety protocols and operating procedures.
Oversee maintenance and reliability of crushers, mills, conveyors, pumps, flotation cells and other mechanical equipment; develop and implement a comprehensive preventive and predictive maintenance programme.
Lead mechanical projects – equipment overhauls, plant expansions and process improvements – and ensure availability of critical spare parts through effective inventory management.
Analyse equipment performance data to identify trends, recommend improvements, and implement reliability-centred maintenance strategies; ensure compliance with relevant safety, environmental and industry codes.
D. Quality Control & Laboratory
Develop, implement and maintain a comprehensive quality management system so extracted and processed copper, lead and zinc concentrates meet industry standards, customer specifications and regulatory requirements.
Establish and enforce quality control procedures and design testing protocols/methodologies for accurate, consistent product quality assessment.
Oversee inspection and testing of raw materials, intermediate products and final products; analyse data/trends to proactively address quality issues.
Responsible for safe and sustainable functioning of the plant laboratory.
E. Electrical & Instrumentation
Oversee electrical systems management, instrumentation & automation, and control-room operations for the plant.
Ensure all activities comply with the Central Electricity Authority Regulations, 2010 (CEAR, 2010) and other applicable regulatory requirements; drive cost control and energy efficiency.
Oversee quality maintenance and repair of plant equipment to maximise availability and reliability for production; recommend changes to maintenance/operating routines and equipment to reduce downtime and maintenance cost.
F. Production Planning
Direct production planning and scheduling in line with the Project Director's overall direction to ensure production targets are met and customer/project goals satisfied.
Monitor and optimise plant processes for efficient resource utilisation and maximum output; support planning activities and ongoing monitoring of plan-versus-actual performance.
G. Civil Infrastructure & Tailings Management
Oversee civil infrastructure management, including structural integrity assessments and recommending necessary improvements.
Direct tailings storage facility (TSF) management — monitoring for stability, seepage and environmental impact, and implementing best practice for tailings deposition and water recovery.
Evaluate and implement paste plant / paste tailings (backfill) technology as part of the tailings management strategy, alongside conventional TSF deposition, to reduce water usage and improve tailings stability.
Ensure safety and regulatory compliance for all civil and tailings infrastructure; plan and execute civil/tailings projects within budget and timeline, collaborating with geotechnical, environmental and process engineering functions.
H. Organisation & Cross-Functional Coordination
Build, lead and develop the plant embedding a strong safety and quality culture.
Coordinate with the GM (Mining) counterpart on ore blend quality specification and transportation to ensure consistent, specification-grade feed to the plant.
Qualification and Eligibility Criteria:
• B.E./B.Tech in Mineral Processing/Metallurgical/Mechanical/Chemical Engineering, with a mineral beneficiation specialisation preferred
• Minimum 15 years of total experience in mineral processing/beneficiation plant operations, of which:
at least 7 years in plant operations leadership for a polymetallic or comparable base-metal ore, including crushing, grinding and selective/differential flotation to produce multiple concentrates; and
at least 5 years in senior leadership role
• Prior experience commissioning a greenfield concentrator/beneficiation plant – from construction through ramp-up to steady-state production is highly desirable
• Hands-on experience preparing or reviewing a TEFR/DPR and leading process technology and equipment selection for a beneficiation plant is strongly preferred
• Strong background in plant maintenance and reliability, quality management systems, and tailings storage facility management; exposure to paste plant/paste tailings (backfill) technology is an advantage
• Familiarity with CEA Regulations, 2010 and applicable environmental/safety compliance requirements for mineral processing plants; exposure to EPC/technology-licensor contract finalisation and commissioning management
• Strong leadership, cross-functional coordination and stakeholder management skills
Location: Copper Project , Ambaji, Gujarat
Remuneration: The monthly consolidated remuneration will be based on the previous/current remuneration. (Negotiable)
Terms of Contract:
The engagement will be strictly contractual for initial period of two (2) Years, extendable for one year based on performance and business requirement. The candidate will not confer any right for regular appointment in the organization at any point of time. The contract can be terminated by either side at any time by giving one month’s prior notice or pay in lieu of notice period.

Work arrangement
No