Smelter Operation Readiness - Engineer, Process Automation

The purpose of this position :

Designing, implementing, and maintaining automation systems to improve operational enhancement and efficiency, safety, process reliability, and dependable operation of Smelter & Refinery control system. Work collaboratively with other engineers and operators to optimizing and integrating advanced technologies like DCS, PLCs (Programmable Logic Controllers), SCADA systems, and IoT devices into smelting & refining operations.

The key duties and responsibilities of this position:

1. Automation System Design and Implementation

• Design and program control systems for equipment like furnaces, mills, and conveyors.
• Develop and configure PLCs (TIA Portal), DCS (Siemens PCS7), IMS and/or SCADA systems to monitor and control processes.
• Interfacing between DCS and MCC (DOL, VSD and SIPROTEC).
• Implement advanced sensors and IoT solutions for real-time data acquisition.

2. Process Optimization

• Identify opportunities for automation to reduce manual intervention and improve process stability.
• Implement control loops and algorithms for optimized temperature, pressure, level, flow, and analyser control.
• Reduce downtime by automating maintenance alerts and diagnostics.

3. Equipment Integration

• Ensure seamless integration of new automation systems or packages with existing equipment.
• Collaborate with equipment vendors and maintenance teams to ensure compatibility and functionality.

4. Troubleshooting and Maintenance

• Diagnose and resolve issues in automation systems, minimizing production interruptions.

5. Data Analysis and Reporting

• Utilize automation systems to collect and analyse process data for performance improvement.
• Generate reports on production efficiency, equipment performance, and process deviations.

6. Safety and Compliance

• Implement automated safety systems, such as emergency shutdowns and alarm management.
• Ensure automation solutions comply with industry safety standards and environmental regulations.

7. Support

• Engage and collaborate with operators, process engineers, technicians and contractors to execute work assignments.
• Provide technical support for troubleshooting and system upgrades.

The key challenges in this position:

• Process Optimization by balancing efficiency, cost, and quality while maintaining consistent output.
• Raw Material Variability due to inconsistent quality of ore or concentrates affects process stability and output.
• Communicating complex process adjustments to technical team.

The background, education, and work experience needed to succeed in this job are:

• Bachelors Degree or Masters Degree in Physic Engineering, Electrical Engineering or related field with minimum 3-5 years of experience in smelting, refining, or similar heavy industrial processes.
• Having knowledge in PI system.
• Having experience in Virtualization and Industrial Communication Protocols.

Core Competencies (Knowledge, Skills & Characters):

• Knowledge of process simulation software (Training Simulator)
• Analytical thinking for diagnosing and resolving process inefficiencies.
• Knowledge of industrial safety standards and environmental regulations.
• Ability to present findings and recommendations clearly to teams and management.

The key areas that the incumbent have decision-making responsibility:

• Recommend upgrades or automation technologies to improve operational reliability.

Dateline : 14 May 2025