Melt Deck / Refractory Furnace Operator - 1st Shift

About the Role

Refractory and Melt Deck production associates perform a variety of operations tasks to promote the efficient melting and mixing of iron in the Spin Line department. This role involves added technical and mechanical responsibility, including learning mechanical and metallurgical skills to ensure the ideal mix of pour for the entire process.

Responsibilities

• Operate overhead crane to move raw material from the raw material yard to charge cars for the melting process and transfer iron to the holding furnace.
• Weigh material and monitor/add alloys as needed.
• Perform temperature checks on the electric melt furnace.
• Slag furnace to remove impurities from 2650–2800 degree molten iron.
• Charge and operate the furnace to melt materials for the full melt cycle.
• Enter and retrieve data from the computer.
• Perform routine preventive maintenance.
• Pour molten iron from furnace to transfer ladle.
• Perform sintering and cold starts.
• Maintain a clean work environment in accordance with 5S guidelines.
• Operate industrial powered equipment.
• Knock out, pour, and rebuild runner boxes, I-ladles, and slag poles.
• Complete weekly preventive maintenance (PMs) on the melt furnace, including:
  • Knocking out slag from the furnace wall.
  • Inspecting furnace lining.
  • Repairing furnace lining.
  • Setting up the furnace for the next operating day and loading the travel car.
• Repair and rebuild the melt trough.
• Rebuild the melt furnace, including:
  • Removing condo.
  • Cutting trenches in the old lining.
  • Setting the furnace to push out the old liner.
  • Cleaning and inspecting the furnace wall.
  • Repairing the furnace wall and grouting areas of concern.
  • Preparing the furnace for relining, setting forms, and adding materials.
  • Performing relining and setting up the furnace for the centering cycle.
• Dismantle and rebuild vessels, including:
  • Disassembling the vessel.
  • Knocking out old materials and cleaning.
  • Preparing the vessel for reassembly.
  • Pouring lining, reassembling, and setting up for testing.
  • Setting the vessel on heat to dry.
• Knock out and repour bull ladles.
• Repair 50-ton furnaces and #1 and #2 troughs on the spin line.
• Install and repair all refractory work related to operations, including furnaces, iron ladles, troughs, runner boxes, slag paddles, intermediate ladles, and installing nozzles.
• Inspect equipment to detect faulty performance and conditions to avoid breakdowns.
• Document information daily related to refractory work.
• Backup Melt Crane Operator, Transfer Ladle Operator, or Melt Furnace Operator.
• Crosstrain other employees as required.
• Perform all other duties as assigned.

Requirements

• High School Diploma or GED required.
• Ability to obtain certification to drive industrial powered equipment (e.g., forklift).

Physical Demands

• Moderate to heavy physical effort (lift/carry up to 50 lbs with assistance).
• Ability to go up and down stairs multiple times per day.
• Prolonged, extensive, or considerable standing/walking.
• Lift supplies/equipment and push/pull or move/lift heavy equipment/supplies with assistance, depending on weight.
• Manual dexterity and mobility, including considerable reaching, stooping, bending, kneeling, and crouching.
• Far acuity: ability to see clearly at 20 feet or more.
• Near acuity: ability to see clearly at 20 inches or less.
• Depth perception: ability to judge distance and space relationships.
• Field of vision: ability to see peripherally.
• Accommodation: ability to adjust vision to bring objects into focus.

Environmental Conditions

• Extreme heat exposure when working around the slagging furnace.
• Temperature variations from hot to cold depending on weather.

Benefits

• Medical, dental, and vision insurance.
• Life, travel, and disability insurance.
• Flexible spending account.
• 401K plans and a pension plan.
• Paid holidays and vacation.
• Financial assistance programs for adoption or further education.
• Comprehensive wellness program and Employee Assistance Program (EAP) to support proactive health and wellness management.