Assistant General Manager Blast Furnace

Department:

Role Purpose:

To lead and manage the Blast Furnace operations (Furnace, Hot Metal Bay, and Pulverized Coal Injection system), ensuring safe, reliable, and efficient production of hot metal to meet plant requirements. The role involves optimizing furnace productivity, PCI utilization, energy efficiency, cost reduction, maintenance planning, and ensuring adherence to statutory & safety standards.

Key Responsibilities:

1. Blast Furnace Operations Management

• Lead day-to-day operations of the blast furnace ensuring targeted hot metal production (quality, quantity, and consistency).
  
• Monitor furnace health, burden distribution, tuyere condition, refractory wear, gas flow, and hearth performance.
  
• Ensure effective operation of auxiliary systems – cast house, slag granulation, and stockhouse.
  
• Maintain stable furnace operation by optimizing burden mix, coke rate, PCI rate, and oxygen enrichment.
  

2. Hot Metal Bay & Cast House Operations

• Oversee safe tapping, hot metal handling, slag management, and transportation to SMS.
  
• Ensure adherence to SOPs for casting, hot metal/slag skimming, granulation, and ladle management.
  
• Implement best practices to minimize hot metal losses, reduce tapping delays, and improve cast house safety.
  

3. PCI (Pulverized Coal Injection) System Management

• Ensure effective operation and maintenance of PCI system for maximizing coal injection rate.
  
• Optimize coal blend, grinding, drying, injection parameters to reduce coke rate and cost per ton of hot metal.
  
• Monitor PCI system performance, troubleshoot breakdowns, and ensure energy efficiency.
  

4. Production Planning & Cost Control

• Plan and execute monthly/annual production targets in coordination with plant planning.
  
• Optimize fuel rate, raw material utilization, and productivity (THM/m/day).
  
• Drive cost reduction initiatives through increased PCI rate, reduced coke rate, and energy optimization.
  

5. Maintenance & Reliability

• Develop preventive and predictive maintenance schedules for furnace, cast house, and PCI systems.
  
• Coordinate with mechanical, electrical, instrumentation teams for smooth execution of shutdowns and repairs.
  
• Plan capital repairs, relining, and life extension of furnace refractory.
  

6. Safety, Compliance & Environment

• Ensure compliance with statutory requirements (Factories Act, Environment regulations, etc.).
  
• Implement strict safety protocols for furnace tapping, slag handling, PCI operation, and confined space entry.
  
• Drive initiatives for energy conservation, reduction in emissions (dust, SOx, NOx, CO), and slag utilization.
  

7. People Leadership & Training

• Lead a team of engineers, shift in-charges, and operators for smooth furnace operation.
  
• Build technical capability of the team through training in modern BF technologies, PCI operation, cast house safety, etc.
  
• Drive discipline, teamwork, and continuous improvement culture within the department.
  

Key Performance Indicators (KPIs):

• Daily Hot Metal Production vs Target (Tons/day).
  
• Productivity (THM/m/day).
  
• Specific Coke Rate (kg/thm).
  
• PCI Injection Rate (kg/thm).
  
• Hot Metal Quality (Si %, S %, P %).
  
• Furnace Availability & Campaign Life.
  
• Safety performance (Zero LTI, Near Miss reporting, Compliance).
  
• Cost per ton of hot metal.
  

Qualification & Experience:

• B.E./B.Tech in Metallurgy / Mechanical / Chemical Engineering.
  
• 15–20 years of experience in Blast Furnace operations (minimum 3–5 years in a managerial/leadership role).
  
• Strong technical knowledge of BF process, PCI systems, refractory management, and cast house operation.
  
• Hands-on experience in handling BF relining/major repair will be an added advantage.
  

Skills & Competencies:

• Strong leadership and team management skills.
  
• In-depth understanding of BF operation, PCI optimization, and hot metal handling.
  
• Analytical & problem-solving skills for troubleshooting furnace instability.
  
• Knowledge of SAP/ERP systems for production & maintenance management.
  
• Safety-conscious mindset with knowledge of statutory compliances.
  
• Strong communication and coordination skills with cross-functional teams (SMS, RMHS, Coke Oven, Maintenance).