Hazem Nayef

Over 17 years of technical engineering and management leadership across heavy industry, specializing in thermal systems, process optimization, and industrial energy auditing. As a Certified Energy Manager (CEM®), I focus on reducing operational expenses (OPEX) and conducting deep-dive technical facility audits to drive massive energy efficiency improvements. Core Areas of Expertise: Energy Auditing & Process Analysis: Establishing facility baselines, false air mapping, and heat/mass balance calculations to eliminate structural energy waste. Thermal & Steam Systems: Optimizing industrial kilns, burners, fuel splitting configurations, and waste heat utilization. Project Financial Engineering: Linking technical process auditing data with financial feasibility studies to support executive capital expenditure (CAPEX) decisions.

Lead and cooperate with different teams members to do the following: I. Technical evaluation & feasibility studies of new projects. II. Commissioning of new projects as Coal Mill , Burners , Alternative fuel , preheater modifications , inner pipes & others Modifying Fuel Splitting in calciner to eliminate thermal NOx formations in calciner . Locally Modifying the Tertiary entrance to calciner. Commissioning of Bag filters in Raw Mill & Coller areas. CFD studies . Tender Preparation . Constructing Performance Grantee test & Punish list. Implementing actions for Mercury control in stacks by Zero Cost . Meeting new environmental regulations by Reducing Dust Emissions with negligible cost. Enforce standard operation procedures and continuously modifying this SOP to gain agility of team members. Review operational reports, identify root cause for performance gaps, and consider measures to obtain results. Optimizing the Kiln to utilize alternative fuel with ~ 40%, Preparing process flow charts. Cooler Optimization Bypass Optimization, Material & Heat Balance for the lines. False air mapping. Cement Mills Audits including Crash Stops –Ventilation and Aerolic Balance internals inspection. Modification in Cement mills first generation separation by low cost local solutions. Charge Classification and modifications by competitive cost. Vertical Mill Optimization . Localization of Ball mills consumables parts including lifters,media and diaphragm. Coordinates production activities with maintenance, process & quality teams to integrate production interfaces. Change the Philosophy of annual shutdowns to be constructed & measured based on performance figures, which in turn is transferred to saving in our variable cost.

Knowledge Acquired in the position: Learned how to study a plant based on its process figures and propose effective solutions. Learned to study designs and its impact on operation and efficiency, involved in creating tenders and studying payback of many project. I. Working in corporate level to audit 5 cement plants 8 Lines (FLS and Polisus): a. Suez Cement – 2 Polisus Lines, b. Katamya ,Helwan – 1 Polisus Line, c. Tourah Cement – 2 FLS Lines d. Menya Cement – 1 Line White Cement e. Helwan Cement – 2 FLS Lines II. Create and implement the process plan for those lines. III. Conduct complete Kiln & RMs process audits. IV. Calculate and evaluate Heat and Mass balances. V. Preparing process flow charts for all the lines. VI. Measuring Fans Efficiencies and proposing low cost solutions. VII. Measuring Separator efficiencies and proposing low cost solutions. VIII. Optimizing Ball mills Charge though process audits and recommending corrective actions. IX. Sourcing and collecting data for establishing standard process correlations and analysis. X. Creating a Software for Process calculations named “MATRIX” That do some tasks in a user friendly way: Calculations for changes in Gases speed in critical areas as Orifice part, Calciner , Tertiary , which helps in taking decision during upset conditions and fuel matrix changes and other operation changes. Simple Heat and Material balance using specific heat gas mixes calculator based on Janaf tables specific heats. XI. Preparation and collection of a process database. XII. Preparation and collection of a process database. XIII. Troubleshooting process problems for all Plants within the Group. XIV. Preparing Part of Tenders related to Process and new CAPEX, starting from the scope and simulated payback for the project and preparation of punish list afterwards. XV. Studying and analysis of a number of modern cement industry techniques and creating benchmark from them. XVI. Complete calculations and proposing in modifications.

XI. Preparation and collection of a process database. XII. Preparation and collection of a process database. XIII. Troubleshooting process problems for all Plants within the Group. XIV. Preparing Part of Tenders related to Process and new CAPEX, starting from the scope and simulated payback for the project and preparation of punish list afterwards. XV. Studying and analysis of a number of modern cement industry techniques and creating benchmark from them. XVI. Complete calculations (Mass flow - Equipment sizing) and proposing in modifications.

Knowledge Acquired in the position: In this position, I was able to acquire knowledge about different factors that affect kiln operation as: Refractory types and different shapes of defects in refractories. Alternative fuel utilization, impact of moisture and availability of oxygen with AF percentage. Sense of numbers and responsiveness to sudden and gradual pressure and temperatures changes. Impact of thermal splitting between main burner and calciner. Mixes that increase heat consumption while noticing the impact of easy to burn material. Material mix impact on refractory lifetime like the impact of excessive/low liquid phase. Coller air distribution and blowing factor, and burner configuration and its impact on kiln performance. I. Operator for FLS offline double string preheater Kiln (Capacity 5500 TPD). II. Assuring maximum utilization of the kiln and efficient stable operation. III. Participation in preparation of overhauling activities in Kiln area by measuring Kiln bricks thickness. IV. Assuring quality of Bricks and Bricking installations. V. Burner Centralization on site. VI. Assuring refractory tasks in preheater from Kiln inlet , Cyclones roofs, Claciner roofs & shelfs and other critical activities as, inner pipes and pendulum gates installations.

Knowledge Acquired in the position: In this position, I was able to acquire knowledge of operation, the impact of different problems on the mill performance, like the impact of low performance separator, impact of false air on raw mill output, Impact of coated media, impact of in adequate diaphragm slots, impact of finesse required. I. Operator for two FLS air swept Raw Mills. II. Inspection of the mill filling degree. III. Inspection of Internals condition diaphragm slots dimensions. IV. Inspection of separator top seal clearance and overlap. V. Inspection of separator glades angles and numbers.

Knowledge Acquired in the position: In this position I was able to acquire knowledge that correlates between materials impacts on operation therefore gained sense of balance that later enabled me to take decisions easier. I. Working on Shift basis to control Raw Mix. II. Manage the Input raw materials quality. III. X-Ray Calibration IV. Building X-Ray Curves V. Following Raw Mills & Cement Mills Finesse and Blaine VI. Kiln inlet and Bypass analysis VII. Communication the results with the operation team VIII. Monitor and learn the influence of materials composition on the operation of RM, Kiln and Cement mills and disusing them with the operation.

Knowledge Acquired in the position: In this position, I learned different the specs of polymers and different machinery for molding and shaping , learned the impact of different machines configurations on the product quality and cost, learned methods of testing products, like compressive test, tension, and density. I. Perform compressive and tensile strength. II. Product Physical tests including density determination and dimensions assurance, and molding quality . III. Product density measurements to be within accepted tolerance, to determine the temperature of molding machine. IV. Chemical experiments results analysis via informal/formal conversations, reports to a multidisciplinary audience. V. Provide lab assistance to the production team to investigate production deviations. VI. Responsible for maintaining lab equipment, troubleshooting, calibrations, and coordination of repair. VII. Prepare and post SOPs for lab equipment. VIII. Order and maintain inventory of lab supplies IX. Perform other duties as assigned.