Manager / Deputy Manager – Furnace Operation & PCI Job in Chandrapur at Lloyds Metals & Energy Ltd

Key Responsibilities

1. Blast Furnace Operation:

• Oversee daily operations of the Blast Furnace, ensuring smooth and stable process conditions.
• Monitor and control key parameters such as:
• Top pressure and gas distribution.
• Blast pressure, temperature, and humidity.
• Oxygen enrichment and burden descent rate.
• Ensure consistent hot metal output, temperature, and quality (Si, S, P levels).
• Coordinate with the Stock House for burden charging and raw material sequencing.
• Support process optimization to improve productivity, reduce coke rate, and enhance campaign life.
• Lead furnace start-up, shutdown, and relining operations as required.

2. PCI (Pulverized Coal Injection) Operations:

• Supervise PCI system operations for reliable and efficient coal injection.
• Monitor and control:
• Coal grinding and drying parameters.
• Injection rate, pressure, and air/coal ratio.
• PCI equipment performance through PLC/DCS systems.
• Optimize PCI utilization to achieve target coke replacement ratio and maintain furnace thermal balance.
• Coordinate with mechanical, electrical, and instrumentation teams for preventive maintenance and system reliability.
• Analyze PCI efficiency and implement improvements in coal quality, distribution, and injection pattern.

3. Process Monitoring & Control

• Operate and monitor process parameters via PLC/DCS/SCADA systems.
• Record and analyze:
• Hot blast parameters (temperature, pressure, flow).
• Gas composition (CO, CO₂, H₂) and utilization.
• Top gas pressure and furnace temperature trends.
• Take corrective actions for any process deviations such as hanging, slipping, or scaffolding.
• Coordinate with control room and field teams for real-time process adjustments.

4. Production & Optimization:

• Achieve daily and monthly hot metal production targets.
• Maintain optimum fuel rate (coke + PCI) and energy efficiency.
• Analyze operational data for identifying improvement areas and reducing process losses.
• Support process trials, R&D initiatives, and automation improvement projects.
• Collaborate with Process Control and Energy Management teams for optimization initiatives.

5. Safety, Health & Environment:

• Ensure strict compliance with Blast Furnace safety standards and SOPs.
• Conduct safety toolbox talks, near-miss reporting, and hazard identification.
• Enforce LOTO procedures, PPE usage, and safe operating practices for PCI systems.
• Maintain compliance with ISO 45001 / ISO 14001 / ISO 9001 standards.
• Drive initiatives for energy conservation, waste heat utilization, and emission control.

6. Manpower & Shift Management:

• Lead and guide shift in-charges, control room engineers, and field operators in Furnace & PCI areas.
• Prepare and manage shift rosters ensuring round-the-clock operational coverage.
• Conduct regular skill enhancement and process awareness training for team members.
• Ensure effective shift handover communication and documentation.

7. Coordination & Communication

• Coordinate with:
• Hot Blast and Blower House for air and oxygen supply.
• Cast House for tapping sequence and metal despatch.
• Stock House for burden preparation and charging.
• Maintenance & Utilities for preventive and breakdown maintenance.
• Maintain smooth communication between control room and field operations during shifts.

8. Documentation & Reporting

• Maintain accurate records of:
• Furnace performance, cast details, and burden mix data.
• PCI injection rate, coal consumption, and energy utilization.
• Process deviations and corrective measures taken.
• Prepare daily, weekly, and monthly performance reports.
• Support in KPI review meetings, process audits, and management reporting.

Qualifications:

• B.E. / B.Tech / Diploma in Metallurgical / Mechanical / Production / Electrical Engineering from a recognized institution.
• Strong understanding of iron-making fundamentals, blast furnace thermodynamics, and fuel injection systems.

Experience:

• Deputy Manager: 7–10 years of experience in Blast Furnace operation and PCI systems.
• Manager: 10–14 years of experience in furnace process control, PCI optimization, and iron-making operations.
• Experience in integrated steel plants (≥0.5 MTPA Blast Furnace) preferred.
• Hands-on experience with PLC/DCS automation systems (Siemens / ABB / Honeywell) desirable.

Technical Skills:

• Strong command over Blast Furnace operation, burden distribution, and gas flow control.
• In-depth knowledge of PCI system operation and performance tuning.
• Proficiency in DCS/SCADA process monitoring and control logic interpretation.
• Ability to analyze gas utilization, thermal efficiency, and fuel rate performance.
• Familiarity with SAP (PM/MM) and digital process reporting tools.

From commissioning one of the oldest DRI plants in Maharashtra, to pioneering iron ore production in the state while uplifting the places we operate in. Growth which has become synonymous with our performance.
Growth which reflects in our ambitious plans of becoming a world class steel producer. Growth which is not only for us but for the nation at large.