Engineering - Mechanical & IndustrialManufacturing & ProductionFull time
24 Oct
Senior Refractory Specialist
Vadodara, India
20-25 LPA
Full time
Job Description: Senior Refractory Specialist
Department: Engineering / Technical SolutionsPosition: Senior Refractory SpecialistExperience: 15–20+ yearsLocation: Vadodara, Gujarat, IndiaTravel: Extensive domestic and international travelIndustry: Refractory Manufacturing, Refractory Engineering, Industrial Furnaces, Boilers and High-Temperature Process Equipment.
1. Position Overview
We are seeking an experienced Senior Refractory Specialist to provide advanced refractory engineering, design and technical solutions for industrial customers across high-temperature process industries.
The successful candidate will serve as a technical authority for refractory systems used in furnaces, boilers, combustion equipment and other high-temperature process applications. The role involves developing refractory design concepts, selecting appropriate refractory materials, defining lining configurations, reviewing engineering documents and supplier proposals, supporting installation and dry-out activities, and investigating refractory failures throughout the equipment lifecycle.
The candidate will work closely with end-user customers, engineering consultants, EPC contractors, equipment manufacturers, refractory suppliers and multidisciplinary engineering teams to ensure that refractory systems meet operational, thermal, mechanical, chemical and service-life requirements.
This is a senior technical engineering role. Candidates should have substantial experience in refractory design, application engineering, central engineering, technical services or an engineering/technology centre within a refractory manufacturing or refractory engineering organisation. The position is not intended for professionals whose experience is predominantly in sales, marketing, account management or routine plant maintenance.
2. Key Responsibilities
A. Refractory Conceptual Design and Engineering
Develop refractory design concepts for industrial furnaces, boilers, combustion chambers, reformers, incinerators, reactors, ducts and other high-temperature equipment.
Review process operating conditions, equipment geometry, temperature profiles, chemical environments, mechanical loads and expected operating cycles to establish the refractory design basis.
Determine suitable lining configurations, refractory thicknesses, insulation arrangements, expansion allowances and anchoring systems.
Develop and review refractory lining layouts, sectional drawings, detailed engineering drawings and installation details.
Assess thermal gradients, shell temperatures, heat losses, thermal expansion and other relevant design parameters.
Evaluate refractory performance requirements, including resistance to thermal shock, abrasion, erosion, corrosion, chemical attack and mechanical damage.
Identify design risks and recommend engineering improvements to enhance equipment reliability, service life and maintainability.
B. Refractory Material Selection and System Optimisation
Select suitable refractory materials based on operating temperature, process chemistry, thermal cycling, erosion, abrasion, mechanical stress and equipment-specific requirements.
Evaluate and specify appropriate refractory systems, including:
Firebricks and shaped refractory products.
Castables and other monolithic refractories.
Insulating refractories and ceramic-fibre insulation.
Refractory and insulation anchoring systems.
Expansion joints and associated lining components.
Acid-resistant and chemical-resistant lining systems, where applicable.
Determine material grades, layer configurations, thicknesses and combinations of hot-face and backup insulation.
Assess compatibility between refractory materials, anchors, casing, process conditions and adjacent equipment components.
Recommend alternatives or design modifications to improve refractory performance, reduce premature failures and optimise lifecycle costs.
Evaluate the technical suitability of proposed materials and identify potential performance risks before implementation.
C. Engineering Documentation and Technical Specifications
Prepare, review and approve refractory engineering deliverables, including:
Refractory design calculations and design-basis documents.
Technical specifications and material requisitions.
Material selection schedules, datasheets and bills of materials (BOMs).
Refractory lining drawings and installation details.
Insulation and anchoring specifications.
Installation, curing and dry-out procedures.
Inspection, quality-control and acceptance requirements.
Ensure engineering documents are technically complete, consistent with project requirements and suitable for procurement, fabrication and site execution.
Review drawings and documentation prepared by engineering teams, suppliers, consultants and subcontractors.
Maintain appropriate design records, technical justifications, revisions and lessons learned.
D. Technical Evaluation of Supplier and Vendor Proposals
Review technical offers from refractory manufacturers, material suppliers and specialist engineering contractors.
Evaluate material grades, physical and chemical properties, thermal characteristics, installation requirements and compliance with technical specifications.
Review technical deviations, exclusions, alternative materials and proposed design modifications.
Conduct technical bid evaluations and identify gaps between supplier proposals and project requirements.
Clarify technical issues with suppliers, EPC contractors and customers and recommend technically acceptable solutions.
Support procurement teams in technical selection without making sales or commercial account management the primary responsibility.
E. Customer, Consultant and EPC Engineering Support
Work directly with end-user customers to understand operating problems, equipment limitations, process requirements and refractory performance expectations.
Participate in technical discussions with customers, engineering consultants, EPC contractors, OEMs and multidisciplinary project teams.
Present and explain refractory design concepts, material-selection decisions, technical risks and recommended solutions.
Review customer specifications, equipment drawings, operating data and project requirements.
Provide engineering guidance during design reviews, technical clarification meetings and project execution.
Visit customer plants to assess equipment conditions, inspect refractory installations, investigate performance issues and recommend corrective actions.
Coordinate with process, mechanical, thermal, combustion, inspection and commissioning teams to resolve engineering interfaces.
F. Installation, Inspection, Curing and Dry-Out Support
Review refractory installation methodologies, anchoring arrangements, material handling, mixing, placement, ramming, casting and bricklaying procedures as applicable.
Verify that installation practices and quality-control requirements are consistent with the approved design and material specifications.
Review curing and dry-out procedures, including recommended heating rates, holding periods and temperature profiles, according to the refractory system and equipment requirements.
Support site inspections, installation audits, pre-commissioning reviews and technical troubleshooting.
Provide engineering recommendations for first firing, initial start-up and commissioning where required.
Investigate deviations between approved design documents and site installation conditions.
Recommend corrective measures to address installation defects, improper curing, inadequate anchoring or other issues that may compromise refractory performance.
G. Refractory Failure Investigation and Root-Cause Analysis
Investigate refractory failures such as cracking, spalling, erosion, abrasion, chemical attack, premature wear, lining collapse and abnormal shell temperatures.
Review operating histories, inspection findings, failure photographs, maintenance records, installation quality and original design documents.
Identify likely failure mechanisms and distinguish between design deficiencies, material incompatibility, installation defects, operational deviations and maintenance-related causes.
Conduct or coordinate root-cause analysis (RCA) and failure investigations at customer locations.
Recommend corrective and preventive actions, including changes to refractory grades, lining thickness, anchoring, expansion provisions, installation procedures or dry-out curves.
Prepare technical investigation reports and communicate findings to customers and internal engineering stakeholders.
Incorporate lessons learned into future design standards, material-selection guidelines and engineering practices.
H. Technical Leadership and Engineering Excellence
Act as a senior technical authority and provide guidance to refractory design and application engineering teams.
Review complex designs, calculations, specifications and technical recommendations prepared by other engineers.
Establish or improve design practices, engineering checklists, technical standards and quality-review procedures.
Mentor engineers on refractory materials, lining systems, thermal calculations, failure mechanisms and application engineering.
Support knowledge transfer across engineering, procurement, site execution and commissioning teams.
Contribute to continuous improvement initiatives focused on reliability, service life, safety, engineering quality and lifecycle performance.
3. Technical Applications and Industries
Relevant experience may include one or more of the following applications:
Industrial boilers and steam-generating equipment.
CFBC/FBC boilers, biomass combustion systems and combustion chambers.
Industrial furnaces, fired heaters and process heaters.
Steam reformers, cracking furnaces and other high-temperature reactors.
Incinerators, thermal oxidisers and waste-treatment equipment.
Waste heat boilers, high-temperature ducts and associated process equipment.
Petrochemical, refinery, oil and gas, fertiliser and chemical-processing facilities.
Cement, steel, iron, aluminium, copper and other heavy manufacturing industries.
Candidates need not have experience in every application. However, they must demonstrate substantial, technically relevant refractory engineering experience and the ability to apply sound engineering principles to unfamiliar high-temperature equipment.
4. Essential Qualifications and Experience
Bachelor’s degree or diploma in Mechanical Engineering, Materials/Metallurgical Engineering, Chemical Engineering, Ceramic Engineering or a closely related discipline, supported by substantial relevant refractory engineering experience.
Approximately 15–20+ years of relevant professional experience, with significant exposure to refractory design, application engineering, technical services or central engineering.
Experience in a refractory manufacturing company, refractory engineering organisation, specialist engineering centre or an equivalent technical solutions environment.
Demonstrated ability to develop, review or technically approve refractory designs and material-selection decisions.
Experience preparing or reviewing technical specifications, design drawings, BOMs, material requisitions and engineering calculations.
Proven understanding of refractory materials, insulation systems, anchoring arrangements, thermal behaviour and common failure mechanisms.
Experience interacting with end-user customers, consultants, EPC contractors, OEMs or other engineering stakeholders.
Exposure to installation inspection, curing/dry-out procedures, commissioning support and refractory failure investigations.
Strong technical communication, report-writing and problem-solving capabilities.
Willingness to undertake extensive domestic and international travel.
API 936 certification or other relevant refractory engineering, inspection or materials qualifications would be an advantage.
5. Preferred Technical Competencies
The ideal candidate should demonstrate competence in several of the following areas:
Refractory lining design and material selection.
Thermal calculations, heat-transfer analysis and insulation design.
Refractory thickness, temperature-profile and shell-temperature assessment.
Refractory anchor design and material compatibility.
Brick, castable, monolithic and insulating refractory systems.
Technical specification development and supplier proposal evaluation.
Installation quality assessment and dry-out procedure review.
Failure investigation and root-cause analysis.
CAD-based engineering drawings and technical documentation.
Engineering design reviews and multidisciplinary technical coordination.
Knowledge of relevant refractory standards, material-testing practices, installation requirements and engineering software is desirable.
6. Behavioural and Professional Competencies
Strong analytical thinking and a structured approach to technical problem-solving.
Ability to make independent, technically defensible engineering decisions.
Excellent written and verbal communication with customers and senior engineering stakeholders.
Confidence in explaining and defending technical recommendations.
Practical judgement in balancing refractory performance, reliability, safety and lifecycle cost.
Ability to lead technical discussions and work effectively across multidisciplinary teams.
Willingness to travel frequently and work at customer locations when required.
A proactive, customer-focused engineering mindset, with a commitment to technical integrity and continuous improvement.
7. Explicit Candidate Profile Requirements
Priority candidates should have:
Worked in refractory design, application engineering, technical services, technology centres or central engineering functions.
Personally developed or technically owned refractory designs and material-selection decisions.
Supported external industrial customers with engineering solutions rather than only internal production or maintenance activities.
Reviewed technical specifications, supplier proposals and refractory engineering deliverables.
Participated in site-level troubleshooting, refractory failure investigations or installation/commissioning support.
Demonstrated the ability to communicate directly with end users, consultants, EPC contractors and other technical stakeholders.
Profiles that are generally not suitable:
Sales, marketing, business development or account management professionals without strong hands-on refractory engineering capability.
Plant maintenance professionals whose experience is limited to routine refractory maintenance and shutdown coordination.
Site supervisors focused mainly on installation execution, with limited design ownership.
Estimation-only or tendering-only professionals without material-selection, design and technical problem-solving depth.
Candidates whose experience is predominantly in supplier quality or inspection, without broader refractory engineering responsibilities.
8. Key Performance Indicators
Performance in the role may be assessed against:
Technical quality and accuracy of refractory designs and engineering deliverables.
Effectiveness of material-selection decisions and design optimisation.
Timeliness and quality of technical evaluations and customer engineering responses.
Reduction in repeat refractory failures through effective RCA and corrective actions.
Quality of installation, curing and dry-out recommendations.
Customer satisfaction with technical support and engineering solutions.
Adherence to engineering standards, safety requirements and project specifications.
Contribution to technical capability development and continuous improvement.
9. Role Summary
The Senior Refractory Specialist will be responsible for delivering reliable, technically sound refractory engineering solutions across the equipment lifecycle—from concept design and material selection to supplier technical evaluation, installation support, commissioning and failure analysis.
The ideal candidate is a senior refractory engineering professional with deep technical knowledge, proven design ownership, strong customer-facing engineering capability and experience solving complex high-temperature equipment problems. The position requires an engineer who can independently analyse requirements, develop practical solutions and serve as a trusted technical authority for customers and internal engineering teams.