MELTER

Assuming SMS = Steel Melting Shop, a Melter is responsible for operating and controlling the melting process in an induction/electric arc furnace and ensuring production of steel to the required chemistry, temperature, quality, and safety standards.

Job Description — Melter, SMS Operation

Job Title: Melter – Steel Melting Shop (SMS)
Department: Steel Melting Shop / Production
Reports To: Shift In-charge / Melting Shop Manager

Key Responsibilities

• Operate the furnace and associated SMS equipment safely and efficiently.
• Charge scrap, DRI/HBI, pig iron, alloys, and other metallic/non-metallic materials as per the approved charge mix.
• Control the melting process to achieve the required steel grade, chemical composition, temperature, and heat size.
• Monitor furnace parameters such as power/current, voltage, temperature, melting time, slag condition, and electrode consumption, as applicable.
• Take molten-steel and slag samples at required stages and coordinate with the laboratory for chemical analysis.
• Make necessary additions of ferro-alloys, carburizer, deoxidizers, fluxes, and other materials based on heat chemistry.
• Maintain proper slag practice and ensure effective removal of impurities.
• Coordinate with the Ladle Furnace (LF), CCM, crane, refractory, maintenance, and quality teams for smooth heat transfer and casting.
• Ensure correct tapping temperature and chemistry before tapping.
• Minimize metallic losses, slag carryover, power consumption, electrode consumption, refractory wear, and heat-making time.
• Follow standard operating procedures (SOPs), work instructions, and process-control parameters.
• Identify abnormal furnace conditions and immediately inform the Shift In-charge.
• Maintain proper records of heat number, charge materials, additions, temperature, chemistry, tap-to-tap time, and production.
• Conduct routine inspection of furnace, cooling system, hydraulics, electrical systems, and other critical equipment from an operational perspective.
• Ensure housekeeping and proper handling/storage of raw materials and consumables.
• Strictly follow PPE, LOTO, hot-metal safety, electrical safety, fire safety, and SMS safety procedures.
• Support troubleshooting and participate in root-cause analysis for process deviations, quality problems, and equipment-related issues.
• Train and guide helpers/operators in safe and correct operating practices.

Key Performance Indicators (KPIs)

• Heat/tonnage production
• Heat-making or tap-to-tap time
• Yield/recovery
• Power consumption per tonne
• Electrode consumption per tonne, where applicable
• Ferro-alloy and flux consumption
• Tapping temperature and chemistry accuracy
• Rejection/rework due to chemistry or temperature
• Furnace availability
• Safety performance and compliance
• Refractory consumption
• Housekeeping and 5S

Qualification & Experience

• ITI / Diploma in Metallurgy, Mechanical, Electrical, or related discipline; Diploma/B.Tech in Metallurgy is preferred for senior positions.
• Typically 2–8 years of experience in SMS operations, depending on grade and furnace type.
• Experience with EAF/IF, LF, slag practice, steel chemistry, tapping, and heat management is desirable.
• Good understanding of steel grades, ferro-alloy additions, temperature measurement, sampling, and basic metallurgy.
• Ability to work in rotational shifts and in a high-temperature industrial environment.

Core Competencies

• Furnace operation and process control
• Basic steel metallurgy
• Heat chemistry and temperature control
• Troubleshooting and decision-making
• Safety awareness
• Team coordination
• Production and quality orientation
• Shift/heat documentation