Engineer / Sr. Engineer Cast House

Role & responsibilities

Key Responsibilities:

1. Cast House Operations

• Monitor and control

  hot metal and slag tapping

  as per blast furnace tapping schedules.
• Supervise

  taphole opening, closing, drilling, and plugging operations

  to minimize cast delays and ensure safe practices.
• Coordinate with the

  furnace control room

  for cast timing, blast pressure, and furnace condition adjustments.
• Ensure smooth flow of

  hot metal to torpedo ladles or mixers

  with minimal spillage and metal loss.
• Manage

  slag granulation or pit casting

  as per process requirements.
• Maintain detailed records of each cast, including duration, metal/slag yield, temperature, and operational deviations.
  

2. Runner & Refractory Management

• Inspect and maintain

  cast house runner systems

  , troughs, skimmers, and launder arrangements.
• Supervise

  relining, patching, and dressing

  of runners and troughs to ensure continuous operation.
• Monitor and plan

  refractory life cycles

  for runners and troughs to optimize performance and cost.
• Coordinate with the refractory maintenance team for

  timely repairs and relining

  based on wear analysis.

3. Equipment & Utility Management

• Ensure proper functioning of all

  cast house equipment

  , including

  mud guns, tap hole drills, slag granulation units, tilting runners, and skimmers

  .
• Coordinate with

  mechanical, electrical, and instrumentation teams

  for preventive and corrective maintenance.
• Monitor

  granulation water pressure, flow, and recycling systems

  to maintain system efficiency.
• Report abnormalities and initiate corrective actions to minimize equipment downtime.
  

4. Safety & Environment

• Enforce strict

  safety protocols

  for hot metal and slag handling operations.
• Ensure compliance with

  PPE usage, LOTO procedures, and safe working practices

  during casting.
• Maintain high standards of

  housekeeping and safety signage

  in the cast house area.
• Adhere to

  environmental norms

  regarding slag disposal, dust suppression, and water discharge control.

5. Process Optimization & Continuous Improvement

• Analyze

  casting performance data

  to improve metal yield, reduce tap-to-tap time, and optimize cast duration.
• Participate in

  root cause analysis (RCA)

  for cast-related breakdowns or quality issues.
• Support process improvement initiatives such as

  Kaizen, TPM, or Lean projects

  for productivity and cost optimization.
• Suggest improvements in refractory design, runner configuration, or cast scheduling for enhanced efficiency.
  

6. Coordination & Reporting

• Liaise with

  Furnace Control Room, Steel Melting Shop (SMS), and Maintenance teams

  to ensure synchronized plant operations.
• Prepare and maintain

  daily, weekly, and monthly reports

  on cast house performance, metal yield, and refractory consumption.
• Support internal and external

  audits, inspections, and management reviews

  .
• Maintain detailed records of casting data, equipment condition, and maintenance history using

  SAP or plant data management systems

  .

Preferred candidate profile

Qualifications & Experience:

Education:

• Diploma / B.E. / B.Tech in

  Metallurgical, Mechanical, or Production Engineering

Experience:

• Engineer:

  36 years of experience in

  cast house operations

  of a medium to large blast furnace (0.5 MTPA).

• Sr. Engineer:

  6–10 years of experience in

  cast house supervision, refractory maintenance, and process coordination

  in ironmaking operations.

Industry Preference:

• Integrated Steel Plant / Iron Making Unit / Metallurgical Industry
  

Key Skills & Competencies:

• Strong understanding of

  blast furnace cast house process flow

  and hot metal handling.
• Hands-on experience in

  taphole clay management, metal/slag separation, and granulation systems

  .
• Proficiency in

  runner preparation, refractory maintenance, and cast scheduling

  .
• In-depth knowledge of

  safety procedures and risk management

  for high-temperature operations.
• Analytical and problem-solving skills for

  process improvement and root cause analysis

  .
• Strong

  communication, coordination, and leadership

  abilities to manage shift teams and operators.
• Working knowledge of

  MS Office, SAP (optional), and plant data logging systems

  .
• Commitment to

  safety, quality, and operational excellence

  .