Steve Kalonga

I manage the metallurgical database (raw material, production records, plant machinery performance trends) in my section, and I execute the following functions:

• Troubleshooting and identification of technical constraints, and developing corrective action where necessary.
• Monitor plant performance and analyze data to provide performance trends and improvements.
• Critically review operating and technical data to identify trends or non-compliance against the set Key Performance Indicators (KPIs), and work out the corrective measures.
• Ensure that plant operational efficiencies and recoveries are optimized, and ensure that agreed production targets are met while keeping an eye on operations budgeting and cost control systems.
• Maintain performance of all instrumentation at required levels.
• Carry out analysis of thermography images of critical operating equipment.

• Closely monitored all Key Performance Indicators (KPIs) under crushing and lime processes, and implemented initiatives and interventions aimed at meeting production and quality targets.
• Coordinated activities between crushing and lime kilns.
• Coordinated supply of competent, suitable limestone feed for crushing.
• Mobilized manpower for the quick resolution of major breakdowns of plant machinery and equipment.
• Make call-outs if deemed necessary.
• Conducted and facilitated the following routine plant test work during shifts: size distribution analysis using screen and sieve analysis (for both limestone and lime conveyor belt material), conveyor belt (limestone and quicklime) throughput verification test, and HFO flow verification test.
• Update line managers on the plant status during shifts.
• Drive safety initiatives and practices to ensure a safe working environment.

• Generation of Plant start-up and shutdown strategies/procedures for Vertical kiln2 was achieved
• Review on daily basis the lime burning process, identify problems and provide solutions during commissioning
• Calculate the drawing rate which is suitable of generating sufficient kiln suction whilst averting clinker formation AND producing good grade quick lime
• Preparing material flow sheets and determine crusher gaps in line with production schedules
• Determine screening efficiencies and material splits
• Monitor efficiency of weightometers, thermocouples, weigh bridges, flowmeters, gauges and other measuring devises for reliability
• Prepare weekly and monthly reports for plant performance monitoring
• Accurate posting of production figures and consumables in the ERP system (Navision)
• Preparing weekly cost reports for use in expenditure evaluation meetings
• Enforce quality management systems and drive safety initiatives

• Carried out daily plant ore and concentrate stocks in order to produce reports for plant performance monitoring and planning
• Metallurgical accounting and administration
• Provide technical services and practical guidance to operators in ore handling, crushing, grinding, flotation and dewatering so that resources involved are effectively utilized to meet target ore milled and concentrates production
• Carried out laboratory and plant test works (flotation, filtration, flocculation and particle size analysis) to solve problems affecting the plant and for the development of new chemical reagents
• Calibration of plant measurement system
• Reagent preparation and management

• Monitored operations of the grinding and flotation section to ensure that performance parameters i.e
• Grind and density of feed to flotation, copper recovery, and final concentrate grade are adhered to
• Ensured good equipment availability by conducting pre-shift and in-shift checks on status of equipment and acting as a link between production and maintenance crews in the shift
• Supervised subordinates so that they achieve targets in the shift as determined by management
• Compile a concise and accurate report on shift operations of the grinding and flotation section

• Monitored and manipulated plant operating parameters such as mill throughput, mill water addition rates, flotation cell pulp levels, slurry flow rates, air addition rates and reagent addition rates from a computerized distributed control system to ensure smooth running of grinding, flotation and dewatering section
• Liaising very closely with and alert the shift controller, ball mill operator, flotation operator, column operator and pump house operator on changes in circuit behavior and agree on the best corrective action to take
• Follow the correct laid down procedure of plant start up or shut down both under normal or emergence circumstances