Refractory Technician

ITI Refractory Technician Syllabus (English)

Course Overview

• Trade Name: Refractory Technician
• Duration: 2 Years (4 Semesters)
• NSQF Level: Level 5
• Eligibility: 10th Grade Pass with Science and Mathematics
• Objective: To train candidates in selecting, installing, maintaining, and repairing refractory materials used in high-temperature industrial environments, equipping them for roles as refractory technicians, masons, or quality inspectors in steel plants, cement kilns, or glass furnaces, or for self-employment in refractory installation and maintenance services.
• Certification: National Trade Certificate (NTC) by NCVT

Detailed Syllabus

Semester 1

Trade Theory

• Introduction to Refractory Technology: Role of refractories, applications in steel, cement, and glass industries.
• Safety Practices: PPE (heat-resistant gloves, helmets, masks), handling hot materials, fire safety, confined space protocols.
• Refractory Materials: Types (fireclay, silica, alumina, magnesite), properties (thermal resistance, abrasion resistance).
• Tools and Equipment: Trowels, ramming tools, mixers, vibrators; usage and maintenance.
• Masonry Basics: Bricklaying patterns (English, Flemish), mortar types, bonding techniques.
• Furnace Basics: Structure of furnaces, kilns, boilers; role of refractories in heat retention.
• Engineering Drawing: Reading refractory layouts, furnace cross-sections, brick lining diagrams.

Trade Practical

• Safety Drills: Using PPE, handling refractory dust, operating fire extinguishers, practicing confined space safety.
• Tool Handling: Using trowels for mortar application, operating mixers, checking ramming tools.
• Material Testing: Identifying refractory bricks (fireclay, alumina), checking for cracks or defects.
• Bricklaying Practice: Laying fireclay bricks in English bond, preparing mortar mixes (1:4 ratio).
• Furnace Inspection: Observing furnace linings, identifying refractory wear areas.
• Drawing Interpretation: Marking brick layouts based on furnace lining diagrams.
• Project Work: Constructing a small refractory wall section with proper bonding and alignment.

Hours: Theory: 160 hours | Practical: 240 hours

Semester 2

Trade Theory

• Advanced Refractory Materials: Insulating refractories, castables, monolithic linings; composition and uses.
• Installation Techniques: Dry and wet gunning, casting, ramming; achieving uniform linings.
• Thermal Properties: Heat transfer, thermal expansion, insulation efficiency in refractories.
• Refractory Testing: Cold crushing strength, porosity, thermal shock resistance; BIS standards.
• Furnace Operations: Pre-heating, cooling schedules, refractory stress during operation.
• Maintenance Basics: Identifying refractory damage (spalling, erosion), patching techniques.
• Quality Control: Inspection of raw materials, ensuring compliance with industry standards.

Trade Practical

• Material Preparation: Mixing castables, preparing gunning mixes, testing consistency.
• Installation Tasks: Gunning refractory linings, casting monolithic sections, ramming corners.
• Testing Practice: Conducting cold crushing tests, measuring porosity on brick samples.
• Furnace Maintenance: Patching eroded linings, replacing damaged bricks, sealing joints.
• Thermal Checks: Measuring furnace lining thickness, inspecting for thermal cracks.
• Quality Inspection: Checking raw material certificates, verifying brick dimensions (±1mm).
• Project Work: Installing a refractory lining section for a mock furnace with castables and bricks.

Hours: Theory: 160 hours | Practical: 240 hours

Semester 3

Trade Theory

• Special Refractories: Zirconia, chromite, carbon-based refractories; applications in extreme conditions.
• Advanced Installation: Anchoring systems, expansion joints, layered refractory linings.
• Troubleshooting: Diagnosing refractory failures (chemical attack, thermal shock), root cause analysis.
• Refractory Ceramics: Manufacturing processes, sintering, raw material selection.
• Energy Efficiency: Role of refractories in reducing heat loss, insulation design for furnaces.
• Safety Standards: OSHA guidelines, HAZOP studies, refractory dust exposure control.
• Environmental Practices: Recycling refractory waste, managing emissions in furnace operations.

Trade Practical

• Special Material Handling: Installing zirconia bricks, applying carbon-based linings.
• Advanced Installation: Setting up anchors, constructing expansion joints, layering refractories.
• Troubleshooting Tasks: Analyzing spalled linings, repairing chemical corrosion damage.
• Ceramic Practice: Preparing refractory slurry, testing sintering on small samples.
• Energy Optimization: Insulating furnace sections, measuring heat loss reduction.
• Safety Audits: Conducting mock HAZOP studies, checking dust control systems.
• Project Work: Repairing a simulated furnace lining with advanced refractories and joints.

Hours: Theory: 160 hours | Practical: 240 hours

Semester 4

Trade Theory

• Automation in Refractories: Sensors for temperature monitoring, IoT for predictive maintenance.
• Advanced Maintenance: Refractory relining, demolition techniques, large-scale repairs.
• Project Management: Planning furnace shutdowns, cost estimation, workforce allocation.
• Quality Assurance: ISO 9001 standards, six sigma in refractory installation, defect tracking.
• Entrepreneurship: Starting a refractory service business, marketing, trends in industrial refractories.
• Industry Trends: Green refractories, nanotechnology, lightweight insulating materials.
• Regulatory Compliance: Pollution control norms, safety audits for refractory projects.

Trade Practical

• Automation Tasks: Using sensors to monitor lining temperature, logging data for analysis.
• Relining Work: Demolishing old linings, installing new refractory layers, testing integrity.
• Project Execution: Planning a mock shutdown, coordinating tasks, documenting costs.
• Quality Checks: Inspecting installations for defects, preparing QA reports, ensuring ISO compliance.
• Field Exposure: Hands-on training in steel/cement plants or refractory workshops (4-6 weeks).
• Environmental Tasks: Recycling used refractories, inspecting emission control systems.
• Project Work: Complete refractory installation for a simulated industrial furnace, including relining and quality checks.

Hours: Theory: 160 hours | Practical: 240 hours

Additional Components

• Workshop Calculation and Science
  
  • Calculations: Heat loss calculations, refractory volume estimation, mortar mix ratios.
  • Science: Thermal conductivity, chemical reactions in refractories, material science basics.
  • Hours: 80 hours/year
• Engineering Drawing
  
  • Drawings: Furnace lining designs, refractory brick patterns, sectional views of kilns.
  • Hours: 80 hours/year
• Employability Skills
  
  • Communication: Technical reporting, client interaction, teamwork in industrial settings.
  • IT Literacy: Using refractory design software, IoT platforms, online technical resources.
  • Soft Skills: Time management, resume writing, interview preparation.
  • Hours: 60 hours/year

Assessment and Certification

• Exams:
  
  • Theory: Written exams per semester (MCQs, descriptive questions).
  • Practical: Tasks like bricklaying, lining installation, troubleshooting, quality inspections.
• Evaluation Criteria: Installation accuracy, material selection, safety adherence, furnace uptime.
• Certification: NCVT National Trade Certificate (NTC) upon passing all semesters, globally recognized.

Career Opportunities

• Employment: Refractory technician, mason, quality inspector in steel plants, cement kilns, or glass furnaces.
• Self-Employment: Refractory installation services, consultancy for furnace maintenance, material supply.
• Further Studies: Diploma in Ceramic Technology, certifications in refractory engineering or quality control.