BATWELL CHIRWA

Key Responsibilities:

• Oversaw daily monitoring and reporting of Isasmelt furnace refractory wear, providing actionable insights to enhance furnace life.
• Ensured accurate data entry and storage of operational logs using the PI System.
• Developed oxygen, silica, and lime specifications for optimal concentrate blending during smelting.
• Monitored key process indicators, including lance performance, slag composition, matte quality, and bath temperatures.
• Installed and maintained refractory and gas space thermocouples for thermal performance tracking.
• Supervised feed and reagent weigher systems, including calibration and bulk testing.
• Conducted quarterly thermographic surveys of the furnace shell and led monthly performance reviews.
• Managed reagent and fuel reconciliations, monitored inventory levels, and supported procurement decisions.
• Compiled smelter energy and fuel usage reports to support efficiency and cost-saving initiatives.
  
  Achievements & Contributions:
• Led air velocity surveys that informed upgrades to Isasmelt shell cooling fans, significantly reducing wear rates.
• Played a pivotal role in the third refractory re-lining, including thermocouple installation and startup heat-up curve development.
• Investigated and mitigated refractory wear caused by high carbon feeds by optimizing particle size and bath stability.
• Developed a real-time condition monitoring tool that contributed to maintaining plant availability above target.
• Participated in trials to reduce coolant consumption by introducing water into the bath and optimizing coolant size.
• Supported concentrate blending optimization through strategic external sourcing, improving furnace throughput and lining durability.
• Collaborated on the redesign of splash blocks and lance components to address premature failures and extend operational life.
• Currently engaged in coolant reduction initiatives to improve tapping reliability and overall furnace stability.

Key Responsibilities:

• Monitored furnace refractory wear using thermocouple data and heat flux via cooling water systems.
• Performed weekly furnace expansion measurements and reported findings to engineering and operations teams.
• Oversaw daily MSEF operations and compiled monthly technical review reports and presentations.
• Developed and updated log sheets and PI System trends to aid CROs in plant control and monitoring.
• Designed Excel-based tools for condition monitoring of cooling water systems and key plant equipment.
• Conducted daily production reviews, ensuring critical parameters stayed within operational targets.
• Led site-based sampling and test work to support process optimization initiatives.
• Assisted and led projects aimed at improving plant performance and operational efficiency.
• Provided technical troubleshooting and process insights to operations and maintenance teams.
• Updated Piping & Instrumentation Diagrams (P&IDs) in line with project modifications.
• Drafted operating procedures, risk assessments, and safe work instructions.
• Supervised and supported technical aspects during plant shutdowns.
• Ensured regular safety audits, hazard reporting, SOP reviews, and safety talks were carried out.
  
  Achievements & Contributions:
• Identified optimal installation points for pyrometers on slag skimming launders, enabling real-time slag temperature monitoring and reducing probe usage costs.
• Contributed to installation of online load cells on MSEF tie rods, improving expansion force monitoring and reducing manual work in confined areas.
• Enhanced refractory wear tracking through replaceable thermocouples installed via cooling jackets during MSEF’s second refractory campaign.
• Improved occupational hygiene on the slag tapping floor by redesigning off-gas extraction hoods and upgrading suction fans.
• Delivered PI Visio, ProcessBook and Datalink training to interns, CROs, and technical staff, enhancing data usage across departments.
• Participated in the trial installation of fiber optic thermocouples for advanced refractory monitoring, including concept design and materials sourcing.
• Led the MSEF coke conveyor screen upgrade, minimizing coke loss and reducing cleanup time without disrupting plant operations.
• Revised MSEF bath operation parameters to address furnace build-up, including successful supervision of pig iron use.
• Developed Excel tools to optimize electrode regulation and coke charging distribution for improved process control.
• Resolved flow imbalances in MSEF’s closed cooling water circuits, reducing equipment trips due to low flow alarms.

Key Responsibilities:

• Conducted weekly SO₂ gas strength sampling using Reich test methods and advised operations on process control adjustments.
• Validated sulphuric acid production accuracy through reconciliation of tank drop tests, flowmeter readings, and tank levels.
• Created and updated production log sheets based on CRO and supervisor inputs.
• Performed full pressure drop surveys for condition monitoring of catalytic converters and all acid plant units.
• Monitored and reported monthly on anodic protection performance for strong acid heat exchangers.
• Prepared monthly emissions reports for both internal review and external regulatory compliance.
• Verified flow measurements across key utility systems including plant water, raw water, and liquid fuel lines.
• Analyzed operational performance and health of plant equipment and processes, providing technical feedback to relevant teams.
  
  Achievements & Contributions:
• Supported the successful commissioning of several acid plant units.
• Reduced SO₂ packing replacement time by designing a chute loading system and a specialized wash table.
• Improved cooling tower performance by initiating a study on water loss per fan, guiding the adoption of more efficient packing materials.
• Designed a bund wall extension and ramp at the slurry filter, significantly reducing slurry spillage and enhancing housekeeping.
• Identified deteriorated pipework in the wet ESP raw water flush system, leading to successful replacement and flow recovery.
• Developed a PI ProcessBook dashboard for real-time condition monitoring, streamlining troubleshooting for both process and engineering teams.
• Introduced thermographic surveys for acid towers, enabling early detection of hotspots from refractory acid seepage.
• Investigated and addressed design limitations causing poor slurry quality from gas cleaning plant settlers.
• Automated CRO and supervisor reports through basic VBA coding and integration of PI tags, reducing manual logging and paper usage.
• Improved safety during condensate draining at the contact section by designing a system to filter out sulphur trioxide plume, reducing operator exposure risks.