Rao Muhammad Farooq
Malir Karachi
Summary
Accomplished professional specializing in EAF melting optimization and operational effectiveness. Proficient in multitasking, time management, and performing under pressure. Expertise in EAF and LRF processes, including ilmenite smelting, routine lining maintenance, and slag modification techniques. Proven ability to optimize energy distribution and enhance furnace productivity while maintaining strict adherence to safety standards.
Overview
20
20
years of professional experience
Work history
Process Metallurgist (EAF & LRF)
Tasnee ASIC
Jizan, Saudi Arabia
2023.01 - Current
- Oversaw metallurgical processes within ilmenite smelting plant, ensuring optimal operation of electric arc furnace and ladle refining furnace.
- Spearhead ilmenite smelting operations using AC electric arc furnace technology to optimize high‑temperature reduction processes.
- Implemented advanced techniques in ilmenite-based ac furnace smelting processes, focusing on operational efficiency and improved metallurgical results.
- Controlled furnace parameters to maintain optimal energy distribution and facilitate reduction reactions, supporting stable ilmenite smelting performance and consistent product quality.
- Executed comprehensive metallurgical control during ilmenite smelting operations at industrial scale, utilizing advanced techniques to support titanium dioxide and titanium chemical production.
- Conducted in-depth analysis of ilmenite reduction kinetics, focusing on slag formation dynamics and iron separation techniques in AC furnace operations.
- Optimized furnace operations by troubleshooting abnormalities, thereby enhancing slag and stabilizing processes.
- Resolved technical issues swiftly to minimize production downtime.
- Developed innovative metallurgical procedures to enhance operational effectiveness across production lines.
- Compiled detailed reports of production activities for management review and strategic action planning.
Supervisor LRF Steel Making
SOLB Steel Company
Jazan, KSA
2012.08 - 2022.11
- Assisted in preparation and execution of EAF, LRF, refractory, and scrap-yard 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. - Optimize 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 programmed 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.
- Alerted concerned parties regarding any abnormalities in process or grade to facilitate prompt corrective action.
- Analysis shortfall and abnormalities within process and suggest technical change where necessary.
- To maintain inventory of different Ferro alloys and consumable involved in production.
- To report all production activities including breakdown and downtime 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, Pakistan
2006.12 - 2012.07
- Worked in Peoples Steel Mills (Karachi Pakistan)
- Operated 20-ton electric arc furnace with VLB/Lumar system, 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 EAF consumables within established norms.
- Performed routine checks on EAF refractory maintenance.
- Contributed to reduction of EAF 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
Balochistan, Pakistan
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.
Supported mixing of charge materials with SOP.
Helped in repairing furnaces and maintaining refractory components.
Ensured production targets were met by monitoring tap-to-tap times and manpower allocation.
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, PakistanDAE (03 years) - Metallurgy & Material science
Pakistan Steel Institute of Technology
Karachi, PakistanMatric - Science
Sania public school
Karachi, PakistanSkills
- EAF melting optimization
- Multitasking and time management
High-pressure performance
Operational effectiveness - EAF and LRF processes
- Refractory selection expertise
Routine lining maintenance
Slag modification techniques
Optimized energy distribution - Furnace productivity improvement
- Workplace safety adherence
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, LF, 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.
PROFESSIONAL SYNOPSIS
Metallurgical and mechanical professional with 17 years of experience in Electric Arc Furnace (EAF), Ladle Refining Furnace (LRF), and secondary steelmaking operations up to 140T EBT. Strong expertise in continuous DRI feeding (Door Lance / VLB / CONSO), charge mix optimization, slag engineering, refractory life enhancement, and cost-effective steel melting. Experienced in Cupola and Induction Furnace operations. Additionally, over 3 years as a Process Metallurgist at Tasnee ASIC, supporting ilmenite-based EAF operations aligned with titanium dioxide and titanium chemical production. Committed to delivering high-quality metallurgical solutions, operational efficiency, and safe steelmaking practices.
PROFESSIONAL KEY RESPONSIBILITY
- Operational Planning & Management
- Responsible for EAF / LRF/ CCM/ Scrap Yard /Refractory Operations (like, Production, Maintenance/Shutdown, Raw Material, Ladle & Resource Planning)
- Responsible for Process Standardization & Implementation in consideration with user friendly.
- Coordination with inter and intro Department& safety.
- Conceptualizing, planning & executing the Operational Improvement Projects leading to Productivity Improvement, Environment& Safety Standards, and Process improvements.
- Planning effective Shutdown Schedules of process equipment to increase equipment up time, Equipment availability, thereby accomplishing planned production targets within budget.
- Process Improvement
- Developing of Standard Operation Procedures to increase the plant efficiency and output.
- Managing activities right from the conceptualization stage to the execution, scheduling and progress monitoring.
References
References available upon request.
Timeline
Process Metallurgist (EAF & LRF)
Tasnee ASIC
2023.01 - Current
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 (03 years) - Metallurgy & Material science
Pakistan Steel Institute of Technology
Matric - Science
Sania public school