Deputy Manager /Assistant Manager EAF Operation

Sarthee Consultancy; Hyderabad; On-site; INR 1,500,000 - 2,100,000; Full time

Job summary

Sarthee Consultancy is seeking an experienced EAF Operations Manager to supervise and optimize electric arc furnace melting cycles, ensuring safe, stable operations at our Hyderabad plant. The role involves planning charge mixes, monitoring power input, slag control, and refining steel chemistry in coordination with LRF/VD teams, while driving cost reduction and TPM-based improvements.

You will lead engineers and operators, coordinate maintenance, enforce SOPs, and foster a culture of safety,

Qualifications

• B.E./B.Tech in Metallurgical, Mechanical, Electrical, or related engineering discipline.

Responsibilities

• Supervise and control EAF operations to ensure stable, efficient, and safe melting cycles.
• Plan and execute the charge mix, including scrap, DRI, and pig iron, as per heat plan and grade requirements.
• Monitor and control power input, electrode regulation, oxygen blowing, and carbon injection parameters.
• Ensure proper slag control to achieve desired refining and phosphorus removal.
• Optimize tap-to-tap time, specific energy consumption, and electrode consumption to reduce operating costs.
• Monitor furnace lining, roof, and electrode performance; coordinate with refractory teams for relining or patching.
• Record heat-wise operational parameters and analyze deviations for continuous improvement.
• Maintain steel chemistry and temperature at tapping in coordination with LRF and VD requirements.
• Ensure deoxidation, slag formation, and addition of alloys as per metallurgical standards.
• Coordinate with the laboratory for heat sample analysis and timely corrections.
• Optimize operational parameters to reduce nitrogen content and improve steel cleanliness.
• Implement and ensure adherence to SOPs for EAF operation.
• Ensure proper functioning of EAF equipment including transformers, electrodes, furnace roof, shell, tilting mechanism, cooling system, burners, and lances.
• Coordinate with Mechanical, Electrical, and Instrumentation maintenance teams for planned and unplanned maintenance.
• Plan and support furnace shutdowns, relining, and major overhauls.
• Ensure availability and reliability of auxiliary systems including fume extraction, cooling water, and power distribution.
• Maintain zero-incident operations through adherence to SMS safety procedures.
• Conduct pre-start safety checks and ensure all operators follow PPE and safety SOPs.
• Manage safe handling of hot metal, scrap charging, and slag disposal operations.
• Ensure compliance with pollution control norms particularly for fume extraction and dust collection systems.
• Promote and enforce 5S and housekeeping standards in the furnace area.
• Continuously monitor EAF productivity and cost performance metrics including power consumption, electrode usage, refractory consumption, and yield.
• Conduct Root Cause Analysis for delays, trip events, and equipment breakdowns.
• Implement process improvement and energy optimization projects using TPM, Kaizen, and Six Sigma methodologies.
• Work on improving yield, reducing power consumption, and minimizing tap-to-tap time.
• Coordinate operations with Raw Material Handling, LRF, VD, and CCM teams for smooth heat flow.
• Ensure proper ladle scheduling and heat sequencing to avoid bottlenecks.
• Maintain accurate shift records, heat logs, and production reports.
• Participate in daily production and coordination meetings with operation and maintenance teams.
• Lead and supervise engineers, shift in-charges, and operators.
• Ensure proper manpower deployment for each shift and operational activity.
• Conduct training sessions on EAF operation, safety, and troubleshooting.
• Motivate the team to achieve production and safety targets.
• Evaluate team performance and promote a culture of accountability and skill enhancement.

Skills

Team leadership

EAF operations

Process optimization

Safety compliance

Troubleshooting

Education

B.E./B.Tech in Metallurgical/Mechanical/Electrical

Job description

Role & responsibilities

Key Responsibilities

EAF Operation Management

• Supervise and control EAF operations to ensure stable, efficient, and safe melting cycles.
• Plan and execute the charge mix, including scrap, Direct Reduced Iron (DRI), and pig iron, as per the heat plan and grade requirements.
• Monitor and control power input, electrode regulation, oxygen blowing, and carbon injection parameters.
• Ensure proper slag control to achieve desired refining and phosphorus removal.
• Optimize tap-to-tap time, specific energy consumption, and electrode consumption to reduce operating costs.
• Monitor furnace lining, roof, and electrode performance; coordinate with refractory teams for relining or patching.
• Record heat-wise operational parameters and analyze deviations for continuous improvement.

Process and Metallurgical Control

• Maintain steel chemistry and temperature at tapping in coordination with LRF and VD requirements.
• Ensure deoxidation, slag formation, and addition of alloys as per metallurgical standards.
• Coordinate with the laboratory for heat sample analysis and timely corrections.
• Optimize operational parameters to reduce nitrogen content and improve steel cleanliness.
• Implement and ensure adherence to Standard Operating Procedures (SOPs) for EAF operation.

Equipment Maintenance Coordination

• Ensure proper functioning of EAF equipment including transformers, electrodes, furnace roof, shell, tilting mechanism, cooling system, burners, and lances.
• Coordinate with Mechanical, Electrical, and Instrumentation maintenance teams for planned and unplanned maintenance.
• Plan and support furnace shutdowns, relining, and major overhauls.
• Ensure availability and reliability of auxiliary systems including fume extraction, cooling water, and power distribution.

Safety and Environmental Compliance

• Maintain zero-incident operations through adherence to SMS safety procedures.
• Conduct pre-start safety checks and ensure all operators follow PPE and safety SOPs.
• Manage safe handling of hot metal, scrap charging, and slag disposal operations.
• Ensure compliance with pollution control norms particularly for fume extraction and dust collection systems.
• Promote and enforce 5S and housekeeping standards in the furnace area.

Process Optimization and Cost Control

• Continuously monitor EAF productivity and cost performance metrics including power consumption, electrode usage, refractory consumption, and yield.
• Conduct Root Cause Analysis (RCA) for delays, trip events, and equipment breakdowns.
• Implement process improvement and energy optimization projects using TPM, Kaizen, and Six Sigma methodologies.
• Work on improving yield, reducing power consumption, and minimizing tap-to-tap time.

Coordination and Reporting

• Coordinate operations with Raw Material Handling, LRF, VD, and CCM teams for smooth heat flow.
• Ensure proper ladle scheduling and heat sequencing to avoid bottlenecks.
• Maintain accurate shift records, heat logs, and production reports.
• Participate in daily production and coordination meetings with operation and maintenance teams.

Team Management and Development

• Lead and supervise engineers, shift in-charges, and operators.
• Ensure proper manpower deployment for each shift and operational activity.
• Conduct training sessions on EAF operation, safety, and troubleshooting.
• Motivate the team to achieve production and safety targets.
• Evaluate team performance and promote a culture of accountability and skill enhancement.

Preferred candidate profile

Qualifications and Experience

• B.E./B.Tech in Metallurgical, Mechanical, Electrical, or related engineering discipline.

• Assistant Manager: 6 to 10 years of experience in EAF operations in integrated or mini steel plants.
• Deputy Manager: 10 to 14 years of experience in EAF operation with exposure to secondary metallurgy (LRF, VD).
• Preference for experience in integrated steel plants with EAF-based steelmaking units.