Muhammad Zahir

Production / Process Optimization Engineer (Cement)

Personal Information

Permanent Address: Upper Colony, Street 08, H-321, E-mail: zee_nfciet@yahoo.com

Pirmahal, District Toba Tek Singh, Punjab, Pakistan WhatsApp No: +92-3006563224
Mobile No: +964-7737124734
Current Address: Najmat Al Samawa Company for Date of Birth: 02 January, 1989
Cement, 25 KM Al Salman Road, Samawa Iraq Languages: English, Arabic Urdu, Punjabi

OBJECTIVE:

Intend to build a career with progressive organization as cement process engineer where I can design,
develop and optimize different chemical and physical processes utilizing my knowledge, skills and potentials.

ACADEMICS
2008 -2012: B.Sc. Chemical Engineering: CGPA 3.71 / 4
NFC Institute of Engineering and Technology Multan
2006-2008: F.Sc (Pre-Engineering): 74.90%
Superior Science School M.Garh (B.I.S.E D.G.Khan)
2004-2006: Matriculation (Science) 76.95%
Govt High School Pirmahal (B.I.S.E Faisalabad)

Professional Experience (9.0 Years)

(Jan-2021 – To date) Najmat Al Samawa Company for Cement, Iraq (3500 TPD)

 Working as Pyro Process engineer, Product cost controller and Process optimization engineer
 Responsible for organizing and lead for major process audit programs and development of action plans in line with
industry best practices
 Responsible to assist in annual planning process providing the key process and operational targets
 Commissioning and optimization of all equipment (Crushers, Raw Mill, Kiln, Cement Mills and Packing Plant)
 Monitoring and developing action plans to manage inventory, maintenance cost, product cost and other
Manufacturing overheads
 Responsible for tracking of budgets, KPI’s, preparing action plans for improvement and follow up with concerned
 Responsible of Production report (Daily, Weekly and monthly)
 Responsible of refractory planning and execution
 Responsible for material planning and tracking (raw material and additives)
 Responsible for energy efficiency of the plant
 Implementation & responsible of SAP (Business One) process Module, mapping and interact with internal teams
And external vendor to trouble shoot and resolve application complex problems
 (July-2016 – Jan-2021) Bestway Cement Limited Farooqia, Pakistan
(3700 TPD, 6500 TPD)
Assistant Manager Production- Kiln, Raw Mills & Coal Mill
Responsibilities:

 Responsible to prepare monthly costing report & action plan to reduce production cost
 Responsible to prepare budget (OPEX and CAPEX) & monitoring to execute within specified time
 Responsible to monitor maintenance cost and inventory as per annual business plan and presentation in
monthly Performance meeting.
 Responsible to produce desired volume of clinker as per annual business plan
 Close monitoring & controlling of specific fuel consumption, power consumption.
 Shutdown activities like selection, execution of refractory job in kiln, cooler and preheater section
 Actively involved in flow measurements and data interpretation for analyzing specific problem
 Planning and supervising of on-site process audits
 Development of operating procedures and process control plans
 Monitoring and interpreting the daily quality results
 Responsible for improving efficiency in quality and emissions by applying continuous improvement
processes
 Handle responsibilities of accessing and providing recommendations in the domain of control changes and
operations
 Carrying out heat balance, Mass balance and Air balance for optimizing the system

(October, 2013 – July, 2016) Kohat Cement Company limited, Pakistan

(6700 TPD)
Assistant Manager (Production & Quality department)

Responsibilities:
 Troubleshooting at plant site through technical and managerial skills
 Responsible for monitoring and supervising process control parameters to ensure high capacity usage and
update the reports to the Team Manager
 Leads daily interaction with the plant managers to discuss and evaluate performance of Kiln, Raw mill,
Cement mill and the resulting impact on overall production
 Informing and training operations staff and advise on plant
 Daily Production report and stoppages report of Plant
 Optimization of Pyro process, Raw mill, Coal mill and Cement mill
 Responsible for providing technical guidelines in the burning of hazardous fuels to technical staff
 Familiar with energy reduction and cost savings in cement Industry
 Ensured quality of products by regular interaction with the QC Department.

Quality Control Experience

Management Trainee at Kohat Cement Company limited, Pakistan (6700 TPD)

 Sound knowledge of blending, crushing, and kiln processing of geological elements

 Comprehensive knowledge of the processes and materials used in handling tasks in Cement Industry
 In-depth knowledge of raw geologic materials and its chemical compositions and Raw mix design
 Handled responsibilities of fuel (Coal) and perform its Proximate analysis effectively
 Handled the task to perform chemical Analysis of raw material, Clinker and cement by wet chemical
method and XRF analysis
 Knowledge of coal Sampling & Tests according to ASTM Standard
  Water analysis (PH determination, P&M alkalinity, Hardness, TDS, Chlorides, Silica, Iron, Phosphate )
 Instruments used (PANalytial CUBIX XRF analyzer, Bomb Calorimeter LECO-AC 500, Sulphur analyzer,
whiteness machine Konica Minolta CR 410 & Hunter lab England, Atomic Absorption Spectrophotometer
(Perkin Elmer A200)

Projects (Executed)

 Commissioning of 3500 TPD cement plant (Najmat Al Samawa Cement Iraq)

 Successful commissioning of Line-2 (5500 TPD) at Bestway Cement Limited Farooqia
 Optimization / Up gradation of Line-2 from 5500 TPD to 6500 TPD at Bestway Cement Limited
 Implementation of SAP (A1 HANNA) in BCL FRQ and SAP Business B1 in NAS Cement Iraq
 Utilities Power consumption optimization to reduce SPC
 Low cost fuel mix optimization by utilizing local, Afghan coal & Carbon powder to reduce fuel cost
 Up gradation of cooler fans & EP fans for sustainability (3700 TPD) at Bestway Cement Limited
 Optimization of KPI’s (SHC 712 KCal/Kg Clk & SPC 82 KWH/Ton Cement) through false air control /
developing action plans to minimize repetitive breakdowns / controlling of idle power consumption.
 EP’s & bag houses inspection and maintenance to meet dust emission target (<30 Mg/Nm3) at BCL
 Consumption of alternative fuel (Pet coke) to reduce fuel cost (400 Rs/Ton Clk) at BCL
 Optimization of WHRPP Generation (1.2 MW/hr) and reduction of clinker temp by upgrading clinker
cooler fan and MFR adjustment at BCL
 Preparation of chemical solution to reduce volatility of SO2 and conversion to SO3 to maximize high sulfur
fuel (In Progress)
 Maintenance cost reduction by replacing Castable installed areas by Alumina bricks refractory /
modifications to maximum refectory life at BCL
 Raw Mills feed optimization / Up gradation at BCL

Personnel Interest and Skills

 Plant optimization / Maintenance and Safe operation to reduce production cost

 Renewable Energy and alternative fuels
 To explore new opportunities to minimize power consumption and energy cost and maintenance cost

Achievements

 Spotlight award by Bestway Cement Limited

 ISO 9001-2015 and ISO 14001-2015 internal auditor transition training
 Participated in Innovative Competition for Engineers (ICCE 2012)