Success-Story: RefraPredict

RefraPredict: Advancing the Use of Recycled Raw Materials in High-Temperature Applications

The Challenge: Ensuring Reliable Refractory Performance with Recycled Materials

Refractory materials play a critical role in high-temperature industrial applications, such as metal production and ceramics manufacturing. Traditionally, these materials rely on high-purity raw materials, which are becoming increasingly scarce and expensive, particularly within the EU. As industries move towards a circular economy, there is a growing need to incorporate secondary (recycled) raw materials into refractory production.

However, impurities in recycled materials can affect the thermomechanical properties of refractories, potentially reducing their lifespan and performance. Refractory producers, especially SMEs, need reliable methods to predict and guarantee the durability of refractories using secondary raw materials.

The RefraPredict project tackled this challenge by investigating how impurities affect refractory materials and developing innovative testing methods to evaluate their long-term behavior under realistic operating conditions.

The Solution: A Scientific Approach to Material Performance Prediction

RefraPredict introduced a new, dynamic testing system that simulates real-life industrial conditions, considering both thermal gradients and mechanical loads. This approach allowed researchers to study how impurities influence refractory performance more accurately than traditional static tests.

The project focused on high-alumina monolithic refractories, which are widely used due to their excellent heat resistance. By analyzing the effects of different impurity levels, the project provided manufacturers with clear guidelines on how to integrate recycled materials without compromising quality.

Key Achievements and Innovations

• New Testing Methodology
  
  • Developed dynamic high-temperature testing that accounts for thermal gradients and mechanical stress, providing more realistic performance predictions.
  • Enabled refractory producers to identify safe impurity levels that do not negatively impact material properties.
• Improved Use of Recycled Raw Materials
  
  • Provided clear guidelines for manufacturers to optimize raw material composition.
  • Demonstrated that small amounts of liquid phases from impurities can actually enhance thermo-mechanical properties, making refractories less brittle and more resistant to stress.
• Practical Benefits for SMEs and Industry
  
  • Reduced dependence on costly primary raw materials by increasing the use of recycled alternatives.
  • Lower production costs while maintaining high-quality standards.
  • Improved sustainability by reducing waste and supporting circular economy goals.

Impact on the Industry

The results of RefraPredict have been shared with refractory producers in Germany and Poland, particularly SMEs, allowing them to incorporate the findings into their production processes.

Manufacturers now have:

• Reliable data on the effects of impurities, enabling them to fine-tune refractory formulations for optimal performance.
• A better understanding of how to process and anneal materials containing secondary raw materials, ensuring stable and long-lasting refractories.
• Access to new research techniques that could shape future industry standards.

Several Polish manufacturers have already implemented the project’s conclusions, refining their recipes for refractory products with secondary raw materials.

Future Prospects and Ongoing Research

Building on RefraPredict’s success, the project consortium has submitted a follow-up research proposal (CORNET 38th Call for Proposals). The new project aims to:

• Expand the research on technological developments for recycled refractory materials.
• Utilize the prototype testing system developed in RefraPredict for further material innovations.
• Strengthen international collaboration in the standardization of new measurement techniques for refractory materials.

Conclusion

RefraPredict has transformed the way refractory producers approach recycled raw materials, providing them with scientific insights and practical tools to ensure high-quality, long-lasting refractories. By balancing sustainability with performance, the project has paved the way for a more resource-efficient and cost-effective refractory industry.

RefraPredict is not just about predicting refractory behavior—it is about reshaping the industry’s future.