ReSoURCE Project

Helping to innovate refractory recycling for a sustainable and resilient future

Eligibility United Kingdom

Kris Wadrop

Managing Director, Materials

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Revolutionising refractory recycling

Refractory Sorting Using Revolutionizing Classification Equipment (ReSoURCE) project is a 4‑year project that’s aim is to ensure the green and digital transformation of the refractory recycling value chain.

The initiative, led by RHI Magnesita and funded by the EU Horizon program, aims to innovate the full process chain with an AI-supported multi-sensor sorting system. Combining laser-induced breakdown spectroscopy and hyperspectral imaging with optimised pre-processing and automated ejection will lay the foundation for a new state-of-the-art refractory sorting system starting with particle sizes below 1 mm.

$Refractory-Materials$

The challenge

Refractories are specialized ceramic materials that withstand extreme temperatures, chemical exposure, and mechanical stress. They are essential in high-temperature industrial processes, such as steelmaking, glass production, cement manufacturing, and metal refining. Currently, the method of recycling refractory material presents significant challenges.

Once a refractory lining reaches the end of its lifecycle, it is removed from industrial equipment, often resulting in the unavoidable mixing of different material qualities. This contamination complicates the recycling process, making recovering high-purity secondary raw materials difficult. Spent refractories also undergo chemical and structural transformations due to prolonged exposure to extreme heat and harsh operating conditions. These changes can alter phase composition, introduce impurities, and impact the mechanical and thermal properties of the recycled material. The coarse ceramic microstructure and surface contamination also hinder effective sorting and processing.

Vision

To address these challenges, the ReSoURCE project is developing advanced automated sorting solutions using cutting-edge technologies such as Laser-Induced Breakdown Spectroscopy (LIBS), Hyperspectral Imaging (HSI), and Artificial Intelligence (AI). These innovations improve sorting accuracy, enable local recycling, and expand the potential applications of spent refractories in sustainable manufacturing. By overcoming these barriers, the project supports circular economy goals, reduces waste, and minimizes the carbon footprint of industrial materials.

The ultimate project target is to develop automated sorting solutions for refractories with the following features:

• High reliability and robustness

• Handling of entire breakout, including fines

• Highest sorting accuracy for spent refractories

• Mobile character to enable local sorting at customers

• Approved sustainability benefits by Lifetime Cycle Assessment (LCE)

• Enable material usage for alternative products

How is CPI helping?

CPI plays a crucial role in the ReSoURCE project by providing expertise in materials analysis, lifecycle assessment, and process innovation to enhance the recycling of spent refractories. As a leading research and technology organisation, CPI is helping to develop advanced methods for sorting, processing, and repurposing refractory materials, supporting the transition to a more circular economy.

One of CPI’s key contributions is conducting a lifecycle assessment (LCA) and techno-economic analysis to evaluate the environmental and economic benefits of recycled refractory materials. This work ensures that the solutions developed within the project improve recycling efficiency and contribute to sustainability goals by reducing carbon emissions and reliance on virgin raw materials.

Additionally, CPI is exploring new applications for recycled refractory materials and assessing their performance in various industries, such as construction, coatings, and composite materials. Through surface modification techniques and material characterization, CPI is helping to optimize these secondary raw materials for integration into new products.