Electrical Arc Furnace (EAF) Specialist

Role Summary

Key Responsibilities

• Provide specialized EAF engineering and metallurgical support throughout the project lifecycle, from basic engineering and design development through procurement, construction, cold/hot commissioning, and performance guarantee testing.

• Review EAF and steel melting shop (SMS) design deliverables, including equipment layouts, process descriptions, electrical single-line diagrams, cooling water schematics, oxygen/fuel lancing provisions, and technical specifications.

• Support the technical evaluation and integration of EAF systems, including furnace shells, tilting mechanisms, roof lifting/swinging, electrode arms, high-current busbars, furnace transformers, and static var compensators (SVC).

• Review electrical load profiles, harmonic distortion mitigation, flicker control, electrical protection coordination, and power quality requirements associated with high-capacity EAF operations.

• Coordinate electrical, automation, and mechanical interfaces between the EAF and upstream facilities (scrap yard, continuous DRI/HBI feeding systems) as well as downstream units (Ladle Furnace, Vacuum Degassing, Continuous Casting Machine).

• Review automation and Level 1/Level 2 process control architecture for the EAF, including electrode regulation systems, burner/lance automation, scrap preheating control, and metallurgical modeling systems.

• Review technical specifications, equipment datasheets, requisitions, vendor drawings, and sizing calculations for EAF mechanical, electrical, and auxiliary packages.

• Participate in technical bid evaluations, vendor assessments, design reviews, and technical clarification meetings with major EAF equipment manufacturers and technology providers (e.g., Tenova, Danieli, SMS Group, Primetals).

• Coordinate with technology partners, engineering consultants, OEMs, and EPC/EPCM contractors to resolve design issues, technical deviations, and interface bottlenecks.

• Monitor engineering and manufacturing progress of major long-lead EAF equipment packages and ensure timely review and closure of vendor document submissions and technical queries.

• Identify design gaps, constructability and maintainability concerns (such as refractory relining access and electrode handling), and opportunities for energy efficiency and value engineering.

• Provide technical support during construction and installation, including review of field changes, resolution of site queries, and verification of mechanical/electrical erection against approved vendor drawings.

• Support inspection, testing, and commissioning activities, including factory acceptance tests (FAT), site acceptance tests (SAT), cold trials, electrical no-load testing, hydraulic/pneumatic testing, and hot commissioning heats.

• Coordinate with commissioning and future plant operations teams to develop standard operating procedures (SOPs), maintenance strategies, spare parts planning, and operator training programs.

• Support initial plant start-up, power-ramp up, electrode consumption optimization, slag foaming practices, and performance guarantee test runs.

• Ensure EAF designs and operating procedures comply with applicable US codes, standards, electrical safety, molten metal safety, and environmental emission regulations.

• Participate in HAZID, HAZOP, safety-in-design reviews, constructability reviews, and project risk assessments, ensuring all action items are tracked and closed.

• Maintain technical documentation, design review registers, interface logs, technical query trackers, and progress reports for the EAF and associated SMS packages.

Qualifications & Experience

• Bachelor’s degree in Metallurgy, Electrical, Mechanical, Production Engineering, or a related discipline.

• 10–20 years of relevant operational, engineering, or project execution experience focused on Electric Arc Furnace (EAF) steelmaking within integrated steel plants or mini-mills.

• Hands-on background in EAF steelmaking operations, process optimization, refractory management, and electrical/automation system integration.

• Strong understanding of EAF electrical power systems, furnace transformers, flexible cables, high-current conductors, electrode regulation, and fume extraction systems (FES).

• Working knowledge of modern steelmaking practices, including high-DRI/HBI charge mix, scrap management, slag foaming, chemical energy injection, and tap-to-tap time reduction.

• Ability to review and interpret engineering drawings, P&IDs, electrical schematics, control narratives, and equipment specifications.

• Experience working with multidisciplinary project teams, engineering consultants, EPC/EPCM contractors, and global technology OEMs.

• Knowledge of relevant North American or international industrial standards, electrical codes, and heavy manufacturing safety requirements.

• Strong technical problem-solving, analytical, communication, coordination, and stakeholder-management skills.

Preferred Experience

• Prior experience in a greenfield integrated steel plant project, specifically covering the DRI–EAF–SMS–CCM route.

• Direct plant-floor experience as an EAF Metallurgist, Shop Superintendent, or Lead Furnace Engineer prior to transitioning into large-scale project execution roles.

• Familiarity with advanced EAF technologies, such as Consteel systems, twin-shell furnaces, continuous feeding setups, or advanced off-gas heat recovery systems.

• Proven track record in successful cold/hot commissioning and performance ramp-up of new EAF installations.