Maruthi Prasad
General Manager – Sponge Iron Division | DRI & Captive Power Plant Operations
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About
Senior operations professional with over 25 years of experience in coal-based Direct Reduced Iron (DRI) rotary kiln plant operations, including 50, 100 and 150 TPD kiln configurations and integrated Waste Heat Recovery Boiler (WHRB) and AFBC captive power operations. Experienced in end-to-end plant operations, raw material procurement planning, commissioning and process stabilization, production planning, cost control, quality systems, environmental controls, PFMEA and root cause analysis. Progressed from Graduate Engineer Trainee and Shift Incharge roles to General Manager – Sponge Iron Division.
Experience
Technical Consultant - SMS & Sponge iron Division - ILC IRON & STEELS PRIVATE LIMITED - Koppal, Karnataka
(2026-07)
Plant: 2 × 150 TPD Preheater sponge iron plant with WHRB and AFBC 8 MW captive power plant.
- Responsible for overall sponge iron plant operations.
- Responsible for annual and monthly operational planning, raw material procurement planning and production-related requirements.
General Manager – Sponge Iron Division - MS METALS & STEELS PRIVATE LIMITED - Koppal, Karnataka
(2025-07 - 2026-05)
Plant: 2 × 150 TPD Preheater sponge iron plant with WHRB and AFBC 8 MW captive power plant.
- Responsible for sponge iron plant operations, production planning and process requirements.
- Responsible for PFMEA and root cause analysis on process problems to control recurrence.
General Manager – Sponge Iron Division - VRKP ISPAT PRIVATE LIMITED - Bellary, Karnataka
(2024-09 - 2025-07)
Plant: 2 × 100 TPD & 1 × 150 TPD Preheater sponge iron plant with WHRB and AFBC 12 MW captive power plant, with 1 × 350 TPD project under process.
- Responsible for overall sponge iron plant operations and operational planning.
- Responsible for air and water pollution control of the plant.
General Manager – Sponge Iron Division - M/S. KAMACHI INDUSTRIES LTD - Gummidipoondi, Tamil Nadu
(2007-06 - 2024-07)
Plant: 4 × 100 TPD sponge iron plant with WHRB and 10 MW captive power plant.
- Responsible for operations of the overall sponge iron plant.
- Responsible for annual and monthly operational planning and review.
- Responsible for achieving desired product quality while keeping cost of production under control.
- Responsible for planning and scheduling raw material procurement as per the production plan.
- Responsible for achieving targets by training and educating process crew on technical and soft skills.
- Responsible for implementing ISO 9001:20015 and BMQR.
- Responsible for air and water pollution control.
- Responsible for PFMEA and root cause analysis on process problems to control recurrence.
Senior Manager - M/s. Kanishka Steel Industries Ltd
(2005-11 - 2006-10)
Plant: 2 × 100 TPD kilns commissioning & process stabilization.
Manager (Production) - M/s. Hospet Ispat Sponge Pvt. Ltd
(2004-11 - 2005-10)
Plant: 2 × 100 TPD kilns commissioning & process stabilization.
Senior Shift Incharge – Control Room & Equipment Operation - M/s. Kumar Metallurgical Corporation Limited
(2003-08 - 2004-10)
Plant: 2 × 100 TPD plant.
Graduate Engineer Trainee & Shift Incharge - M/s. Aditya Sponge & Power Pvt. Limited
(2001-09 - 2003-05)
Plant: 2 × 100 TPD plant.
Education
B. Tech - Metallurgy & Material Technology - Mahatma Gandhi Institute of Technology / J.N.T.U (2001)
Board of Intermediate - Telangana (1996)
SSC - Z.P. High School, Garla, Khammam (Dist.), Telangana (1994)
