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Chapter 8
Refractory Storage Guidelines

Warehouses in most cement plants are intended to serve as

storage of refractory materials. A good refractory storage
warehouse shall have the following conditions, as shown in
Fig. 8-1.

1. Good roof condition; no holes and good for rainstorm

protection.
2. Good ventilation and air passage and free from
moisture or humidity.
3. Strong floor condition; dry and contains no cracks.
4. Appropriate space allocation to encourage work
efficiency.

Such storage warehouse conditions are ideal, however there

maybe some constraints or limitations, thus good
management is required to achieve the best possible storage
given the constraints and limitations.
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Fig. 8.1: Picture illustrating the condition of an ideal

warehouse

8.1 Suggestions for storage guidelines

Below are some essential guidelines for the storage of

refractory materials:

- Store the most expensive refractory materials that are

sensitive to water and moisture at the best available
location.
- If needed (given the capacity limitation of the
warehouse), the refractory materials that are not
sensitive to water and moisture can be stored in the
open space.
- A stack of more than four pallets of refractory
materials should be avoided.
- The refractory materials should be kept away from
rainwater and moisture as much as possible.
- Once they are exposed to the water and moisture, dry
them fast.
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- The storage locations of each pallet shall be made

accessible by forklift.
- In storing the refractory materials, they should be
separated by types and shapes for easy retrieving
when use.

Types of Refractory Intensity Suitable storage

Materials of damage area
from water

• Fireclay Bricks No or less Open Space

• High Alumina Bricks damaged
• Insulating Bricks Moderately Dry warehouse
• Castables damaged with good roof
• Mortar (Wet type) and air ventilation
• Basic Bricks Severely Dry warehouse
• Spinel Bricks damaged with good roof
• Dolomite Bricks and air ventilation
• Castable
• Mortar (Dry type)

8.2 Disposal of used refractory materials

Whenever a refractory maintenance is performed, it is usually

accompanied by the removal of unwanted refractory
materials and structures that cannot be reused. The solid
waste generated must be disposed off by observing proper
sanitation in order not to cause harm to the environment. The
disposal procedures are to be performed differently according
to the type of refractory materials, as listed below:

8.2.1 Fireclay Bricks, High Alumina Bricks, Heat Setting

Bonding Mortars, Refractory Plastics, Insulating
Bricks and Refractory Castable
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These refractory materials are environmentally

friendly; therefore they can be disposed on a landfill.
However, if possible, it is a better option to reuse or
recycle them in the production process (as raw
materials).

8.2.2 Basic Refractory Bricks can be classified into 2 types:

8.2.2.1 Refractory bricks without Chromium Oxide content

This type is an environmental friendly material;
they can be disposed on landfill, reuse or recycle.
8.2.2.2 Refractory bricks with Chromic Oxide content This
type is non-environmental friendly, as it contains
Trivalent Chromium Compound (Cr+3) and in high
temperature condition with alkali mixture, the
compound will transform into Hexa-valence
Chrome Compound (Cr+6), which is toxic.

Therefore, this type of brick shall be carefully

managed. The best option is to reuse/recycle them
in the production process as a raw material of
Portland Cement Production, with the mixing ratio
that may not give any significant effect. However,
they can be disposed on landfill, which locate far
from underground water sources (water aquifer)
and river basin.