Rao Muhammad Farooq
Malir Karachi,Pakistan
Summary
Experienced Metallurgical Engineer with a strong focus on LRF Refining optimization and operational effectiveness. Demonstrates expertise in EAF and LRF processes, slag engineering, and refining reactions, ensuring precise temperature and metallurgical control. Skilled in alloy addition, heat chemistry adjustment, De-sulphurization, de oxidation process troubleshooting. Adept at electrode regulation and consumption optimization to enhance furnace productivity while maintaining safety standards through 5S and risk management practices. Committed to advancing energy distribution techniques for improved slag modification and overall efficiency.
Overview
20
20
years of professional experience
Work history
Process Metallurgist (EAF & LRF)
Tasnee ASIC
Jizan
2023.01 - 2026.06
- Oversaw metallurgical processes within ilmenite smelting plant, ensuring smooth operation of electric arc furnace and ladle refining furnace.
- Facilitated ilmenite smelting operations using AC electric arc furnace technology for high-temperature reduction processes.
- Maintained optimal energy distribution by controlling furnace parameters, ensuring stable performance in ilmenite smelting.
Supervisor LRF Steel Making
SOLB Steel Company
Jazan Economical City
2012.08 - 2022.11
- Assisted in preparation and execution of LRF operations.
- Operated 150-ton Electric Arc Furnace / Ladle Refining Furnace, ensuring efficient scrap melting operations.
- Supported operational planning activities, ensuring coordination of production and maintenance schedules.
- Facilitated planning of raw material and ladle availability, contributing to resource deployment for efficient operations.
- Optimise daily production plans based on resource availability to ensure efficient workflow.
- Standardize and implement process improvements across teams to enhance operational efficiency.
- Assisted in preparation of start-up procedure checklists.
- Supported planning of shutdown processes.
- Contributed to successful execution of operational protocols.
- Implemented operational improvement projects aimed at boosting productivity while adhering to rigorous safety and environmental standards.
- Developed standard operating procedures to enhance efficiency and output.
- Facilitated training programme to elevate skills and knowledge of junior-level staff.
- Assisted in identifying training needs for employees.
- Supported preparation of training matrix to align with company protocols.
- Facilitated training sessions to enhance organizational capabilities.
- Coordinated effectively with caster personnel and crane coordinator to ensure timely crane availability for ladle supply to caster.
- Optimized operations through implementation of efficient processes and strategic resource allocation.
- Analysis shortfall and abnormalities within process and suggest technical change where necessary.
- To maintain inventory of different Ferro alloys and consumables involved in production.
- To report all production activities including breakdowns and down times to manager production.
- Achievements:
- Achieved highest ladle refractory life of 110 through strategic management of safety and cost-efficiency.
- Enhanced productivity by managing daily operations to achieve average of 24 heats per day.
- Supported staff and technicians in enhancing productivity and quality awareness.
- Assisted in development and delivery of training sessions to improve team performance.
- Encouraged culture of continuous improvement among team members.
Junior Executive LRF Steel Making
Peoples Steel Mills
Karachi
2006.12 - 2012.07
- Worked in Peoples Steel Mills (Karachi Pakistan)
- Operated 20-ton Electric Arc Furnace / Ladle Refining Furnace, ensuring efficient scrap melting operations.
- Coordinated shift manpower to maintain efficient production processes and minimize disruptions.
- Optimized production processes to enhance output during shifts through effective communication and strategic planning.
- Optimized heat production processes to enhance efficiency and minimize costs.
- Facilitated close coordination with production shop organs responsible for charge preparation of EAF process at LRF and continuous casting, leveraging available communication facilities and infrastructure.
- Assisted in producing variety of special and alloy steel grades.
- Worked with over 150-200 types of steel through scrap yard, EAF, LRF, VD, CCM, and ingot casting routes.
- Utilized steel scrap and occasionally DRI in production processes.
- Oversaw manufacturing production of low alloy, medium alloy, high alloy, and ultra-low carbon steel, ensuring adherence to quality standards.
- Key Accountabilities:
- Supported shift-level productivity through effective teamwork.
- Ensured heat size and quality standards were met during shift.
- Monitored crew safety protocols for all shift members.
- Assisted in development of job skills for shift crew.
- Maintained LRF consumables within established norms.
- Contributed to reduction of LRF power electrode consumption.
- Documented production activities in melt shop utilizing advanced analytical tools to generate comprehensive reports for regulatory authorities.
Production supervisor
Bolan Casting Ltd
Baluchistan
2006.03 - 2006.11
- Managed shift operations of 10-ton induction furnace and cupola furnace.
- Coordinated planning and processing of heats to align with PPC planning and power supply.
- Ensured optimal furnace health and upheld safety standards in workshop environment.
- Assisted in executing heat-making processes based on provided plans.
- Aided in supervising alloys consumption and induction and cupola furnace teams.
- Maintained safety standards and 5S principles in workplace.
Education
B-Tech - Mechanical
Indus Institute of Higher Education
Karachi, Pakistan09.2009
DAE - Metallurgy & Material science
Pakistan Steel Institute of Technology
Karachi, Pakistan07.2006
Matric - Science
Sania Public School
Karachi, Pakistan05.2002
Skills
- EAF melting optimization
- LRF secondary steelmaking
- Multitasking and time management
- High-pressure performance
- Operational effectiveness
- EAF and LRF processes
- Slag engineering and refining
- Temperature and metallurgical control
- Alloy addition and heat chemistry
- Desulfurization and Deoxidation Process troubleshooting and control
- Electrode regulation and optimization
- Slag modification techniques
- Optimized energy distribution
- Furnace productivity improvement
- Safety management and risk assessment
LANGUAGES KNOWN
English - Advanced
Urdu - Proficient (C2)
Arabic - Intermediate
INDUSTRIAL TRAINING & COURSES
- Pakistan Steel Mills. Karachi – June / July, 06 - 04 Weeks – Sintering, B.F, IMD, SMD, LD Converter, Cold Rolling, Foundry & pattern making shop, etc.
- Peoples Steel Mills Ltd., Karachi - Dec, 06 - 04 Weeks – EAF, L.F, VD/VOD/VCD, ESR, CC, Rolling Forging & Testing.
- Peoples Steel Mills Ltd., Karachi - June, 08 - 01 Day – Overhead crane, shilling and rigging safety awareness course.
- Peoples Steel Mills Ltd., Karachi - Feb, 08 - 01 Day – Driving and road safety awareness course.
- Pak Swiss Training Centre PCSIR Karachi - Aug., 08 - 09 Weeks – Dies and Mould Technology.
- Peoples Steel Mills Ltd., Karachi - Jan, 10 - 01 Day - ISO 9001:2008 Quality awareness course.
- Pakistan Vacuum Society, Islamabad - Dec, 10 - 05 Days – Applied Vacuum Technologies.
REFERENCES
References available upon request.
Timeline
Process Metallurgist (EAF & LRF)
Tasnee ASIC
2023.01 - 2026.06
Supervisor LRF Steel Making
SOLB Steel Company
2012.08 - 2022.11
Junior Executive LRF Steel Making
Peoples Steel Mills
2006.12 - 2012.07
Production supervisor
Bolan Casting Ltd
2006.03 - 2006.11
B-Tech - Mechanical
Indus Institute of Higher Education
DAE - Metallurgy & Material science
Pakistan Steel Institute of Technology
Matric - Science
Sania Public School