Plant Manager

Plant Manager ZLD Plant, Agucha (HZL)

Organisation Title: Plant Manager

Functional Title: Plant Manager ZLD (HZL Agucha)

Reporting To: Head of Operations

Location: Agucha Mines, Bhilwara, Rajasthan (HZL site)

Team Size: Approx. 60 personnel across three rotating shifts

Employment Type: Full-time, resident at site

CTC / Compensation: Matching with experience, as per company norms

Role Overview

As Plant Manager, you will lead the end-to-end operations and maintenance of the 4.8 MLD Zero Liquid Discharge (ZLD) Plant at Agucha, Rajasthan, built and operated by CleanEdge Resources Pvt. Ltd. on a long-term BOOT (Build-Own-Operate-Transfer) basis for Hindustan Zinc Limited (HZL). The plant employs complex, multi-stage treatment technologies including UF-RO membrane systems, MVR-based evaporation, and crystallization operated by a large, multi-disciplinary, multi-shift team. The role carries full accountability for plant performance, water recovery, regulatory compliance, and client relationship management at site, while reporting into the Head of Operations.

1. Operations & Maintenance

• Lead and manage a team of approximately 60 personnel across three rotating shifts to ensure safe, uninterrupted 24x7 plant operations.
• Oversee all plant process units end-to-end, including:

– Pre-treatment: HRSCC (High-Rate Solids Contact Clarifier), sludge thickeners, media filters

– UF-RO (Ultrafiltration – Reverse Osmosis) membrane system

– Desalter system: DSRO (De-Salter high-pressure RO) with fluidised bed reactor (FBR) for sulfate management

– MVR (Mechanical Vapour Recompression)-based low-temperature evaporation and crystallization

– Sludge handling, dewatering, and disposal

• Ensure uninterrupted operations with a sustained focus on process stability, water recovery, scaling/Antiscalant management, and compliance with ZLD norms.
• Drive troubleshooting of membrane fouling/scaling, crystallizer performance, and other process deviations, engaging OEMs and technical specialists as required.

2. Planning & Execution

• Develop and implement daily, weekly, and monthly operations and maintenance plans.
• Forecast and manage requirements for manpower, chemicals (including Antiscalant and process reagents), consumables, and spares.
• Coordinate preventive and breakdown maintenance schedules with internal teams and OEMs (membrane, evaporator/crystallizer, and rotating equipment vendors).
• Drive plant ramp-up, debottlenecking, and capacity optimisation initiatives in coordination with the technical/process design team.

3. People Management

• Supervise shift managers, engineers, operators, and maintenance staff across the site.
• Drive a culture of accountability, safety, and continuous improvement across all shifts.
• Conduct regular performance reviews, on-the-job training, and skill development programs.
• Manage manpower planning, shift rostering, and workforce discipline in coordination with HR.

4. Process Compliance & Documentation

• Ensure strict adherence to SOPs, HSSE protocols, and statutory/regulatory requirements applicable to the site.
• Maintain logs, reports, and documentation required for audits, client reviews, and internal reporting.
• Ensure timely reporting of plant KPIs – recovery %, water quality/TDS, uptime, chemical consumption – to management and client.

5. Stakeholder Management

• Act as the primary site-level interface for HZL (client) representatives, consultants, and vendors.
• Manage day-to-day client relationship at site, including performance discussions and issue resolution.
• Liaise with equipment OEMs and technology partners on commissioning, performance guarantees, and troubleshooting support.

6. Reporting & Coordination with CleanEdge Management

• Provide regular updates to the Head of Operations on plant performance, issues, and improvement plans.
• Coordinate with procurement, HR, and technical support (process design) teams for smooth operations.
• Escalate critical process, commercial, or contractual issues in a timely manner.

Qualifications & Experience

• B.E. / B.Tech in Chemical, Environmental, or Mechanical Engineering; M.Tech or equivalent postgraduate qualification preferred.
• 12 to15+ years of overall experience in water/wastewater treatment plant operations, with significant exposure to ZLD, desalination, or membrane-based treatment systems.
• At least 5 years in a plant-in-charge / plant manager role, leading large multi-shift O&M teams (50+ personnel).
• Strong working knowledge of UF/RO membrane systems, MVR evaporation, crystallization chemistry, and scaling/Antiscalant management.
• Prior experience in BOOT/O&M contract environments is highly desirable; exposure to mining, metals, or heavy process industry sites is an advantage.
• Sound understanding of HSSE systems, statutory compliance, and audit/documentation requirements for industrial plants.
• Demonstrated ability to manage client and OEM relationships independently at a remote/mine-site location.

Key Skills & Competencies

• Strong process and technical troubleshooting ability across membrane, evaporation, and crystallization systems.
• Proven people leadership and team management across multiple shifts.
• Planning and execution discipline – manpower, spares, chemicals, and maintenance scheduling.
• Effective stakeholder and client-relationship management.
• Safety-first mindset with strong ownership of HSSE and regulatory compliance.
• Willingness to be based full-time at a remote mine-site location (Agucha, Rajasthan).