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Furnace Operators control gas, oil, coal, electric arc, or electric induction furnaces that melt metal for casting into various shapes.

Job Duties 

Furnace Operators may:

Weigh metal ingots and scrap metals and load them into furnaces by hand, with hoists, or by directing a crane operator

Regulate the supply of fuel and air going into furnaces or control the flow of electric current and water coolant through electrodes to heat furnaces

Observe metal color and adjust controls to maintain required temperature

Sprinkle chemicals over the surface of molten metal to bring impurities to the surface

Remove impurities from molten metals using strainers

Remove crucibles containing molten metals from furnaces by using a hoist

Record data from each melting process

Position new electrodes over worn electrodes in electric arc furnaces

Tools and equipment used may include:

New technology includes the increased use of automatic computer control of furnaces, a vacuum degassing process that removes impurities from molten metal, and the direct reduction process that treats the ore with hot gases, reducing the ore to pellets of 90-95 percent iron.

OCCUPATIONAL SPECIALTIES

Occupational Specialties included within this MOIScript:

513.462-010 ORE FURNACE OPERATORS operate furnaces to remove moisture, arsenic, or sulfur from ore.

512.662-010 CUPOLA TENDERS control small furnaces to melt and refine iron, scrap metal, and other additives to produce grey iron castings.

512.683-010 CHARGING-MACHINE OPERATORS control charging machines to load open hearth furnaces with materials such as limestone, pig iron, and metal scrap.

512.382-010 OXYGEN-FURNACE OPERATORS operate oxygen furnaces and auxiliary equipment to produce specified types of steel.

512.685-010 FURNACE TENDERS tend furnaces that remelt nonferrous alloyed metals used in diecasting.

512.685-022 METAL RECLAMATION KETTLE TENDERS tend a melting kettle to remelt scrap metal, dross, and skimmings to recover lead, cadmium, zinc, and other nonferrous metals for reuse.

512.684-014 FURNACE CHARGERS charge a smelting furnace with aluminum scrap and ingots and other nonferrous metals, as well as ore, coke, flux, and other materials.

In addition to learning about these specialties, you may also find it helpful to explore the following MOIScripts:

WORKING CONDITIONS AND REQUIREMENTS

Furnace Operators work indoors with other workers. Working conditions in foundries often vary. Recently, many of the foundries have been changing plant layouts and installing modern ventilating systems to reduce heat, fumes, smoke, and dust. Work areas are also noisy. Workers frequently are exposed to potential burns from molten metal, electric current, and chemicals. The injury rate in foundries is higher than the average for manufacturing. Employers and unions are attempting to reduce injuries by establishing safety training programs.

The normal workweek is 40 hours. Furnace Operators working with continuous operation furnaces, such as blast and open hearth furnaces, may be assigned to rotating shifts. Overtime is frequently required to meet deadlines.

Generally, Furnace Operators provide their own safety shoes, helmets, jackets, gloves. Plastic faceshields are provided by the employers.

Furnace Operators may belong to one of several unions such as the United Steel Workers of America; and The International Union, United Automobile, Aerospace and Agricultural Implement Workers of America. Union members must pay dues.

You Should Prefer:

• Activities dealing with things and objects

• Activities of a routine, concrete, and organized nature

• Activities which involve processes, machines, and methods

You Should Be Able To:

• Perform the same work continuously

• See and compare differences of objects and materials

• Follow set procedures

• Rate information using standards that can be measured or checked

• Work within precise limits or standards of accuracy

Math Problem You Should Be Able to Solve:

The speed of a centrifugal compressor is changed from 1,000 to 3,000 rpm. If the compressor originally delivered 2,000 cfm what will the new delivery be?

Reading Example You Should Be Able to Read and Comprehend:

In the conduction and convection mechanisms, the transfer of heat is associated with matter. For radiant heat transfer, however, a change in energy form takes place, from internal energy at the source to electromagnetic energy for transmission then back to internal energy at the receiver.

Writing Example You Should Be Able to Produce:

Prepare an order form for a supply of chemicals necessary for furnace operation.

Thinking Skill You Should Be Able to Demonstrate:

Analytical skills and be detail oriented in assessing and controlling furnace operations.

EDUCATION AND PREPARATION OPPORTUNITIES

NOTE: On-The-Job Training provided by the employer and a High School Diploma may qualify a person for this occupation.

The following education and preparation opportunities are helpful in preparing for occupations in the MOIScript:

***SCHOOL SUBJECTS***

0700 CAREERS , 0900 COMMUNICATIONS , 2200 MATH , 3300 TECHNOLOGY

***VOCATIONAL EDUCATION PROGRAM***

There are no Vocational Education Programs related to this MOIScript

***POSTSECONDARY PROGRAMS***

There are no Postsecondary Programs related to this MOIScript

Search for a College and/or Instructional Program

***APPRENTICESHIP OPPORTUNITIES***

There are no Apprenticeships related to this MOIScript

***MILITARY TRAINING OPPORTUNITIES***

There are no Military Programs related to this MOIScript

E-Learning Courses and Programs

OPPORTUNITIES FOR EXPERIENCE AND METHODS OF ENTRY

Because this work is hazardous, summer and part-time work are not available for persons under age 18.

               School-to-Work opportunities include:

informal apprenticeships

mentorships

job shadowing experiences

touring a local Furnace Operator employer

internships

volunteer work with a Furnace Operator employer

community service work with an agency

Most Furnace Operators enter this field through direct application to employers. Contact unions representing Operators, local offices of the Michigan Works!, and newspaper want ads for assistance. In addition, you should access and search the internet's on-line employment services sites such as:

Michigan Talent Bank

Michigan Works!

                You should also enter an electronic resume on these on-line services.

EARNINGS AND ADVANCEMENT

Earnings vary because of differences in the amount of incentive pay and cost-of-living allowances. Also, the size of a firm, geographic location, and the extent of unionization affect earnings. Furnace Operators in iron and steel foundries have higher average earnings than Furnace Operators in other manufacturing industries earn.

Nationally, in early 2001, production workers employed in the primary metal industries, where most furnace operators were employed, had average hourly earnings of $16.65.

The basic hourly wage of Furnace Operators in the Grand Rapids area averaged $14.46 in mid 2000. These Operators may also earn incentive pay.

In the automobile industry, earnings of Furnace Chargers and Operators ranged from $16.09 to $22.90 per hour in mid 2001. These workers also received a cost-of-living allowance.

Furnace Operators usually receive paid vacations and holidays, sick leave, pension plans, and health insurance. Some also receive dental benefits. In the steel industry, workers may have earnings protection plans which provide additional pay to workers reassigned to lower paying jobs. Technological severance pay may be provided to those laid off due to technological changes and use of new equipment.

Workers usually begin as helpers or laborers. Qualified Furnace Operators may advance to become supervisors. Seniority is one of the more important factors considered in promotions

EMPLOYMENT AND OUTLOOK

Nationally, about 48,000 Furnace Operators were employed in 1998. Employment of Furnace Operators is expected to decline through the year 2008. The industry distribution for Furnace Operators looked like this:

Continued population growth and higher incomes should create a demand for more metal products. However, metals imports and new technology should allow companies to meet the demand with little increase in employment of Furnace Operators.

About 1,700 Furnace Operators are employed in Michigan. Most of them worked in the manufacturing industry.

Employment in this field in Michigan is expected to decline through the year 2006. An average of 30 openings per year is expected. Most of these will be due to the replacement of workers who retire or leave the occupation for other reasons. Additional openings will occur as workers change jobs or occupations. Employment of Operators is not expected to keep up with production increases due to employers using labor saving-saving technology. Giant blast furnaces that allow greater worker output are being built. Open hearth furnaces are being replaced by more efficient basic oxygen and electric arc furnaces. Recently, there has been a stronger demand for steel products due to increases in automotive vehicle production.

MICHIGAN'S EMPLOYMENT OUTLOOK TO 2006

SOURCES OF ADDITIONAL INFORMATION

Printed Occupational information is available upon written request from sources below.

SUMMARY PROFILE

The occupation of Furnace Operator can be summarized by the following:

MOISCRIPTS are Copyright 2003, Michigan Department of Career Development