Cast House Operator

Job Title:

Blast Furnace Cast House Engineer / Senior Engineer

Department:

Iron Making / Blast Furnace

Location:

[Plant Location]

Reporting To:

Cast House Manager / Blast Furnace Manager

Job Purpose:

To ensure safe, efficient, and reliable operation of the Blast Furnace cast house by managing tapping activities, equipment performance, molten metal/slag handling, and compliance with ISO standards (ISO 9001, ISO 14001, ISO 45001).

Key Responsibilities

1. Cast House Operations

• Supervise and execute iron and slag tapping operations as per SOPs.
  
• Monitor tap hole preparation, opening, closing, and runner management.
  
• Ensure continuous and stable hot metal and slag flow.
  
• Coordinate with furnace control room for tapping schedules and furnace conditions.
  
• Maintain cleanliness and operational readiness of cast house floor and runners.
  

2. Equipment & Process Control

• Inspect and maintain cast house equipment:
  
• Clay guns, drill machines, runners, skimmers, cascades, troughs, slag granulation system, etc.
  
• Ensure timely refractory maintenance and runner relining.
  
• Track performance indicators (HM/slag ratio, tapping duration, delays, RCD, hot metal temperature).
  
• Support troubleshooting during cast-house-related furnace instability.
  

3. Safety & ISO Compliance

• Enforce strict adherence to

  ISO 45001 (OHSMS)

  and cast house safety protocols.
• Conduct hazard identification (HAZID), risk assessments, and toolbox talks.
  
• Ensure use of PPE and control of molten metal movement.
  
• Lead investigations for near misses, incidents, and implement corrective actions.
  
• Ensure compliance with

  ISO 9001 (Quality)

  and

  ISO 14001 (Environment)

  procedures.

4. Documentation & Reporting

• Prepare daily tapping reports, delay analysis, and production logs.
  
• Maintain ISO-required documentation:
  
• SOP/SWI, calibration records, process audits, NCR & CAPA records.
  
• Participate in internal & external ISO audits.
  

5. People & Coordination

• Guide junior engineers, supervisors, and cast house operators.
  
• Coordinate with:
  
• Furnace control room
  
• Mechanical & refractory teams
  
• Quality, safety, and production planning departments
  
• Support training and skill development for cast house workforce.
  

Key Performance Indicators (KPIs)

• Hot metal tapping efficiency
  
• Tapping duration & frequency
  
• Cast house downtime reduction
  
• Runner refractory life
  
• Safety compliance (TRIR, near-miss reporting)
  
• ISO audit compliance rate
  
• Quality and temperature consistency of HM
  

Qualifications & Experience

Education:

• B.E./B.Tech in Metallurgy / Mechanical / Production / Chemical Engineering.
  

Experience:

• Engineer: 2-5 years in Blast Furnace / Cast House operations.
  
• Sr. Engineer: 510 years of relevant experience.
  

Skills & Competencies

• Strong knowledge of blast furnace iron-making process.
  
• Understanding of cast house safety and hot metal handling.
  
• Familiarity with ISO 9001 / 14001 / 45001 systems.
  
• Ability to interpret process data and analyze tap performance.
  
• Leadership, communication, and problem-solving skills.
  
• Experience with refractory systems and cast house machinery.
  

Work Environment

• High-temperature environment with continuous operations.
  
• Rotational shifts as required.
  
• Strict safety