Sr. Engineer / Engineer Refractory (Coke Oven)

Sarthee Consultancy; Vapi; On-site; INR 600,000 - 1,000,000; Full time

Job summary

Sarthee Consultancy in India is seeking an experienced refractory maintenance engineer to plan, supervise, and execute relining, repairs, and maintenance for Coke Oven batteries, regenerators, and CDQ units. You will coordinate with operations, safety, and quality teams to ensure compliance with design specs and schedules.

The role involves inspecting oven walls, tracking wear, and supporting trials of new materials, with a focus on cost optimization and safe shutdowns.

Qualifications

• B.E./B.Tech in Ceramic, Metallurgical, Mechanical Engineering or equivalent.
• Engineer: 2 to 5 years of refractory maintenance experience in Coke Oven or similar high-temperature units.
• Sr. Engineer: 5 to 8 years of hands-on Coke Oven refractory systems experience including chamber walls, regenerators, doors, and CDQ.

Responsibilities

• Plan and execute refractory relining, repairs, patching, and maintenance for Coke Oven batteries, regenerators, and CDQ units.
• Supervise refractory installation during shutdowns per design and technical specs.
• Conduct periodic inspections for cracks, bulging, and wear in oven walls, doors, and regenerators.
• Coordinate hot and cold repair jobs including silica brick replacement, guniting, and fettling with operations teams.
• Ensure refractory dry-out and baking schedules are followed during commissioning or relining.
• Track refractory life, wear rate, and consumption trends for all Coke Oven zones.
• Analyze failure modes (spalling, thermal shock, chemical attack) and implement preventive measures.
• Maintain daily/weekly refractory performance data including temperature, pressure, and oven condition logs.
• Support evaluation and trials of new refractory materials for life extension and cost optimization.
• Verify refractory quality, size, and specs during receipt and storage; ensure proper handling to avoid damage.

Education

B.E./B.Tech in Ceramic Engineering, Metallurgical Engineering, Mechanical Engineering, or equivalent

Job description

Role & responsibilities

Key Responsibilities

• Plan and execute refractory relining, repairs, patching, and maintenance activities for Coke Oven batteries, regenerators, and CDQ units.
• Supervise refractory installation during shutdowns, ensuring adherence to design and technical specifications.
• Conduct periodic inspections to identify cracks, bulging, and wear patterns in oven walls, doors, and regenerators.
• Coordinate hot and cold repair jobs including silica brick replacement, guniting, and fettling with operations teams.
• Ensure refractory dry-out and baking schedules are followed during commissioning or relining.
• Track refractory life, wear rate, and consumption trends for all Coke Oven zones.
• Analyze failure modes such as spalling, thermal shock, and chemical attack and implement preventive measures.
• Maintain daily and weekly refractory performance data including temperature, pressure, and oven condition logs.
• Support technical evaluation and trials of new refractory materials for life enhancement and cost optimization.
• Verify refractory quality, size, and specifications during receipt and storage; ensure proper handling to avoid damage or contamination.
• Coordinate with quality and purchase teams for inspection and testing of incoming refractory materials.
• Prepare material issue plans as per maintenance and shutdown schedules.
• Prepare job plans and resource requirements including manpower, tools, and refractory material for all refractory activities.
• Liaise with Mechanical, Electrical, and Operations departments for maintenance coordination.
• Support annual shutdowns and planned maintenance schedules execution ensuring timely completion of refractory tasks.
• Enforce safety protocols during refractory works, especially in confined or hot areas; conduct toolbox talks and safety checks.
• Ensure compliance with environmental and safety regulations during refractory waste disposal.
• Adhere to 5S, ISO 14001, and ISO 45001 standards in the workplace.
• Maintain detailed records of refractory job history, material consumption, and life data.
• Prepare and submit daily job progress and consumption reports to section heads.
• Assist in monthly refractory performance summaries, cost analyses, and audit documentation.
• Support continuous improvement initiatives in refractory maintenance and operation.

Preferred candidate profile

Qualifications & Experience

• B.E./B.Tech in Ceramic Engineering, Metallurgical Engineering, Mechanical Engineering, or equivalent.
• Engineer: 2 TO 5 years of experience in refractory maintenance in Coke Oven or similarly high-temperature units in an integrated steel plant.
• Sr. Engineer: 5 TO 8 years of hands-on experience with Coke Oven refractory systems including chamber walls, regenerators, doors, and CDQ.
• Experience in an integrated steel plant or refractory manufacturing environment is preferred.