Fernanda Silveira
Specific Processes and Technologies Involved in the Recycling of Refractories from Collection to Reuse or Disposal
RHI Magnesita has formulated a global recycling strategy that enables us to integrate recycling into every stage of our value chain, from sourcing and processing to product development and sales. Different refractory recycling solutions are offered to the market, from off-site spot purchase to on-site spent refractory waste management solutions, to be applied based on the optimal waste-to-value approach. From a processing standpoint, the lining concept combines different qualities of refractories to achieve the best performance in customer operation. Processing includes sorting and cleaning spent refractories, stabilization and/or passivation of potential contaminants and processing to achieve final material specifications. R&D plays an important role in the development of processing technology as well as products based on circular raw materials. Our portfolio with a reduced CO2 footprint is driven in the market by our sales and technical marketing force to deliver at least the same performance as the original refractory.
Experiences with Technical Complexities Associated with Recycling Refractory Materials
Spent refractories, extracted from customer aggregates, usually contain a diverse mix of products with varied chemical compositions. Added to that, refractories partly undergo changes in phase composition and chemistry during the customer application. The sensitivity of refractories to impurities can significantly impact the recycling-containing product performance. The relatively small volume of batches from individual aggregates, ranging from a few tons to a few hundred tons, demands agility and thorough quality inspection throughout the recycling process chain. Moreover, it's critical to mention that, on average, 50 percent of the refractory product is consumed in the customer process, thus limiting the overall available feedstock. That’s why RHI Magnesita has been investing quite a lot in technology development, which is extremely important to turn untouched or downcycled materials into higher value-added materials and to improve quality and efficiency from current processes.
"To maximize the transformation of spent refractories (or any kind of recyclable material) into valuable material, it is crucial to understand that industrial symbiosis is needed."
Challenges in Your Business Current Solutions Are Unable to Solve
From a technological standpoint, RHI Magnesita's roadmap is built on pillars. Explore untapped sources from different industries, improve the yield of recycling processes, enhance post-processing and decrease processing costs by optimizing upstream and downstream process steps, which will further encourage the usage of circular raw materials in refractory products. Although RHI Magnesita has considerably increased recycling utilization in recent years, to conclude, the first wave of technological development is crucial to keep pace. Additionally, cross-industrial collaboration and industrial symbiosis will be critical in advancing the green transition within the heavy industry.
Technology Trend That Excites You Most
As mentioned previously, industrial aggregates are complex and technological development is crucial to increase availability, yield and quality of material. As a solution to drive all the roadmap fields, automated sensor-based sorting pushes the boundaries of what is possible in sustainable refractory recycling with a concept to deliver effective separation of reusable materials from waste, maximize the yield from each batch and significantly reduce the amount of waste destined for landfill. The project Refractory Sorting Using Revolutionizing Classification Equipment (ReSoURCE) is a multidisciplinary project and a collaborative initiative involving globally leading technology partners and the European Union. The project focuses on the green and digital transformation of refractory recycling through the innovation of the full process chain, with AI-supported multi-sensor (Laser-induced breakdown spectroscopy and hyperspectral imaging) sorting equipment as its core technology. The project is funded by the EU's Horizon Europe Framework Programme (www.project-resource.eu).
Advice to Professionals Working In Other Companies in Recycling Initiatives in the Refractory Industry
To maximize the transformation of spent refractories (or any kind of recyclable material) into valuable material, it is crucial to understand that industrial symbiosis is needed. RHI Magnesita believes in the power of collaboration, which involves sharing resources between industries to create more sustainable and efficient systems. Working with suppliers and customers together in win-win partnerships will contribute to reducing waste and creating more sustainable products. Clear transparency in initiatives promotes a friendly environment not only for own development but also to invite the market to contribute with technology and innovative ideas. It is important to adapt the current market mindset in the sense that recycling does not need to be an inferior raw material when processed and applied adequately and that the change to a circular economy is not economically driven but sustainable driven. Local-to-local supply reinforces the value chain, which strives for the development of local partners even in a well-connected world. Technology is key to enabling growing demand and unlocking value from currently disposed materials. To believe in the potential results brings the energy necessary to transform the current linear to circular industry.
