Furnace operators monitor and control furnaces in the process of making steel before it is cast into other products. They work in steel mills, and other types of metal refining and processing plants.
A furnace operator works in a control room, directing the operation of furnaces used to produce steel. Generally, you work on an oxygen furnace, although sometimes you may operate open hearth, electric arc or induction furnaces. From the control room, you observe and operate computers and panel boards that control the various systems required to produce steel in the furnace. You receive information from the computer that fives you the specifications for a particular job. Your task is to calculate and adjust the amounts of molten iron, scrap steel and other additives that will be loaded into the furnace and melted into steel.
You weigh the required amounts of each ingredient and instruct the crane operator and other crew members in the loading of the vessels. You also calculate the required temperature and make the appropriate adjustments. When the furnace is ready to be loaded, you operate controls that tilt the furnace into position so that the scrap and iron can be dumped in. The vessel is then returned to a vertical position. During the process, a long rod that injects oxygen into the mixture is lowered into the vessel. This brings down the carbon content of the steel to the desired level.
During a melt, you observe the control panel carefully, watching for any signs of a malfunction. If a problem occurs, you must take the appropriate action to correct the situation whether it involves adjusting the controls, calling a supervisor, or shutting down the system. You also take samples from each melt and analyze the results to ensure that the composition of the steel is correct. After the melt is completed, you tilt the liquid steel into ladles which are taken by crane for further processing.
The furnace operator must perform routine checks on the equipment. You inspect the vessel for cracks or other defects that could stop production and possibly endanger your crew. You are responsible for a specified level of productivity in the mill as well as for the quality of the steel product.
You do not have to be strong to be a furnace operator, since much of your time is spent operating the control panel and monitoring computer screens. Despite this, you must be fit. There may be some physical work involved during inspection and maintenance of the furnace or when a problem arises involving physical adjustments.
A furnace operator must work in extreme temperatures for short periods of time. Despite the fact that the control room is air conditioned, the steel plant gets extremely hot near the furnace area during a melt. The work is also fairly dirty, since you are dealing with metal ore, scrap iron and various other ingredients.
This is both a challenging and extremely responsible position. You must constantly be calculating ingredients, checking to make sure the proportions are correct, and adjusting temperatures for each particular melt. You also control the operation of very large vessels, full of molten metal. You must maintain maximum production efficiency while being alert to any problems or malfunctions that could endanger yourself and other crew members.
Steel furnace operators are trained in-house, by the employer. They work on an hourly rate and are among the highest paid production people in a steel mill. Shiftwork may be required.
To be a successful steel mill furnace operator, you must have an eye for detail and the ability to pay attention. Much of your time is spent operating a control panel and monitoring computers. You must also hae a good grasp of basic mathematics. Each job specification may be different and you must calculate the proportions of scrap steel, molten iron, oxygen, temperature and other ingredients to ensure that the steel is produced correctly.
There is a certain amount of eye-hand coordination required to be a good furnace operator, since you work the controls that shift molten metal from ladle to ladle. You must also have good written and verbal communication skills. You are required to direct other members of your crew during the process, keep accurate reports and be able to enter information into the computer system.
You should be self-motivated and able to work effectively and efficiently with a minimum amount of supervision.