Engineer / Sr. Engineer Cast House

Sarthee Consultancy; India; On-site; INR 900,000 - 1,300,000; Full time

Job summary

Sarthee Consultancy is seeking a competent professional for a Cast House Operations role in India. You will monitor and control hot metal tapping, supervise taphole work, coordinate with the furnace control room, and ensure safe, efficient flow of metals and slag.

You will also manage refractory/runner needs and track performance data. The ideal candidate holds a Metallurgical/Mechanical/Production Engineering degree and has 6–10 years in cast house supervision within ironmaking.

Qualifications

• > Diploma / BE / BTech in Metallurgical, Mechanical, or Production Engineering.
• > Experience in blast furnace cast house operations is preferred.
• > Knowledge of safety, quality and lean improvement practices.

Responsibilities

• Monitor and control casting operations including hot metal and slag tapping as per schedules.
• Supervise taphole opening/closing, drilling, and plugging for minimal delays and safe practices.
• Coordinate with Furnace Control Room for cast timing and furnace adjustments.
• Ensure smooth flow of hot metal to ladles with minimal spillage and metal loss.
• Maintain records of casts, yields, temperature and deviations.
• Support safety, housekeeping and environmental norms in the cast house.

Skills

Blast furnace process

Hot metal handling

Taphole management

Safety procedures

Cast house operations

Refractory maintenance

Process optimization

Root cause analysis

Crew leadership

MS Office / plant data logging

Education

Metallurgical, Mechanical, or Production Engineering

Job description

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.