{"id":19127,"date":"2026-09-20T13:29:46","date_gmt":"2026-09-20T09:59:46","guid":{"rendered":"https:\/\/azarshahab.com\/?p=19127"},"modified":"2026-09-20T13:37:00","modified_gmt":"2026-09-20T10:07:00","slug":"spent-refractories-recycling","status":"publish","type":"post","link":"https:\/\/azarshahab.com\/en\/spent-refractories-recycling\/","title":{"rendered":"From Spent Refractories to High-Value Secondary Raw Materials"},"content":{"rendered":"<h2 style=\"direction: ltr; text-align: left;\">Introduction<\/h2>\n<p style=\"direction: ltr; text-align: left;\">Refractory materials are indispensable components of high-temperature industrial processes, including iron and steelmaking, cement production, glass manufacturing, and non-ferrous metallurgy. These materials operate under severe thermal, mechanical, and chemical conditions and are consequently replaced after a certain period of service. The resulting spent refractory materials constitute a significant industrial waste stream.<\/p>\n<p style=\"direction: ltr; text-align: left;\">The conventional management pathway for spent refractories has historically been dominated by landfilling, downcycling, or low-value applications. However, the increasing cost and environmental impact of virgin <a href=\"https:\/\/azarshahab.com\/en\/%d9%85%d8%ad%d8%b5%d9%88%d9%84%d8%a7%d8%aa\/chamotte\/\">refractory raw materials<\/a>, together with stricter waste-management regulations and the transition toward a circular economy, have created strong incentives for recovering and reusing these materials.<\/p>\n<p style=\"direction: ltr; text-align: left;\">Recent studies estimate that the global refractory industry consumes approximately 35\u2013\u06f4\u06f0 million tonnes of refractory materials annually, generating roughly 28 million tonnes of spent refractories. Steelmaking and cement production represent particularly important sources of these wastes. The objective is not simply waste disposal reduction, but the preservation of the embedded chemical, mineralogical, and energetic value of refractory materials.<\/p>\n<h2 style=\"direction: ltr; text-align: left;\"><a href=\"https:\/\/azarshahab.com\/en\/%d9%85%d8%ad%d8%b5%d9%88%d9%84%d8%a7%d8%aa\/%d8%ac%d8%b1%d9%85%d9%87%d8%a7%db%8c-%d9%86%d8%b3%d9%88%d8%b2\/\">Spent Refractories as Secondary Raw Materials<\/a><\/h2>\n<p style=\"direction: ltr; text-align: left;\">Spent refractories can contain substantial amounts of valuable refractory oxides and non-oxide phases, including: Al\u2082O\u2083, MgO, SiO\u2082, CaO, Cr\u2082O\u2083, SiC, Spinel, Carbon.<\/p>\n<p style=\"direction: ltr; text-align: left;\">For example, spent high-alumina refractories can contain a large fraction of Al\u2082O\u2083 and can therefore potentially replace virgin alumina or bauxite. Similarly, spent MgO-C refractories can provide MgO-rich secondary raw materials.<\/p>\n<p style=\"direction: ltr; text-align: left;\">However, spent refractories are fundamentally different from virgin raw materials because their composition changes during service. They may become contaminated with:<\/p>\n<ul>\n<li dir=\"ltr\" style=\"text-align: left;\">Molten metal<\/li>\n<li dir=\"ltr\" style=\"text-align: left;\">Slag<\/li>\n<li dir=\"ltr\" style=\"text-align: left;\">Cement clinker<\/li>\n<li dir=\"ltr\" style=\"text-align: left;\">Alkalis<\/li>\n<li dir=\"ltr\" style=\"text-align: left;\">Sulfur<\/li>\n<li dir=\"ltr\" style=\"text-align: left;\">Iron oxides<\/li>\n<li dir=\"ltr\" style=\"text-align: left;\">Carbon<\/li>\n<li dir=\"ltr\" style=\"text-align: left;\">Dust and process residues<\/li>\n<\/ul>\n<p style=\"direction: ltr; text-align: left;\">Therefore, selective collection, sorting, and characterization are critical to successful recycling.<\/p>\n<p style=\"direction: ltr; text-align: left;\">A major review over this issue emphasized that although technical feasibility for refractory recycling has been demonstrated, high-value recycling remains limited. The authors estimated that high-value recycling into refractory raw materials represented only a small fraction of total refractory raw-material demand. The identified automated sorting and improved cooperation between refractory producers and recyclers should be considered as important future developments.<\/p>\n<h2 style=\"direction: ltr; text-align: left;\">Material Flow of Spent Refractories<\/h2>\n<p style=\"direction: ltr; text-align: left;\">A particularly important recent study investigated the material flows of spent refractories originating from steel casting ladles (SCLs) and <a href=\"https:\/\/azarshahab.com\/en\/%d8%b5%d9%86%d8%b9%d8%aa-%d8%b3%db%8c%d9%85%d8%a7%d9%86\/\">cement rotary kilns<\/a> (CRKs) in Europe.<\/p>\n<p dir=\"ltr\" style=\"text-align: left;\">For 2022, the study estimated approximately:<\/p>\n<ul>\n<li dir=\"ltr\" style=\"text-align: left;\">\u06f3\u06f2\u06f6kt of spent refractory from steel casting ladles<\/li>\n<li dir=\"ltr\" style=\"text-align: left;\">\u06f7\u06f4kt from cement rotary kilns<\/li>\n<\/ul>\n<p style=\"direction: ltr; text-align: left;\">The fate of these materials was particularly interesting. Approximately 52% of spent refractory from steel casting ladles was landfilled, whereas recycling of cement rotary-kiln breakout material had increased to approximately 42%. Among material recovered by recyclers, approximately 64% of SCL material and 81% of CRK material was used in the production of new <a href=\"https:\/\/azarshahab.com\/en\/%d9%85%d8%ad%d8%b5%d9%88%d9%84%d8%a7%d8%aa\/\">refractory products<\/a>. These results demonstrate an important point: the recycling potential already exists, but the entire material-flow chain is not yet optimized.<\/p>\n<h2 style=\"direction: ltr; text-align: left;\">Processing Technologies<\/h2>\n<p style=\"direction: ltr; text-align: left;\">The conversion of spent refractories into secondary raw materials generally involves several processing steps.<\/p>\n<h3 style=\"direction: ltr; text-align: left;\">Sorting<\/h3>\n<p style=\"direction: ltr; text-align: left;\">Sorting according to the original refractory type and service location is essential. Mixing materials with incompatible compositions can reduce the quality of the recycled product.<\/p>\n<h3 style=\"direction: ltr; text-align: left;\">Crushing and Grinding<\/h3>\n<p style=\"direction: ltr; text-align: left;\">Spent bricks are crushed to generate aggregates and <a href=\"https:\/\/azarshahab.com\/en\/%d9%85%d8%ad%d8%b5%d9%88%d9%84%d8%a7%d8%aa\/%d8%a2%d8%ac%d8%b1%d9%87%d8%a7%db%8c-%d9%86%d8%b3%d9%88%d8%b2-%d8%b3%d9%86%da%af%db%8c%d9%86\/\">fine powders<\/a>. Coarse fractions can replace aggregate fractions, while fine fractions may be incorporated into the matrix.<\/p>\n<h3 style=\"direction: ltr; text-align: left;\">Magnetic Separation<\/h3>\n<p style=\"direction: ltr; text-align: left;\">Magnetic separation can remove metallic iron and steel contamination, which is particularly important for spent <a href=\"https:\/\/azarshahab.com\/en\/%d8%b5%d9%86%d8%b9%d8%aa-%d9%81%d9%88%d9%84%d8%a7%d8%af\/\">steelmaking refractories<\/a>.<\/p>\n<h3 style=\"direction: ltr; text-align: left;\">Carbon Removal<\/h3>\n<p style=\"direction: ltr; text-align: left;\">For carbon-containing refractories, controlled oxidation may be used when carbon removal is necessary for the intended application.<\/p>\n<h3 style=\"direction: ltr; text-align: left;\">Particle-Size Classification<\/h3>\n<p style=\"direction: ltr; text-align: left;\">The recycled material can then be separated into different size fractions and incorporated selectively into refractory formulations.<\/p>\n<h3 style=\"direction: ltr; text-align: left;\">Characterization<\/h3>\n<p style=\"direction: ltr; text-align: left;\">Important characterization techniques include:<\/p>\n<ul>\n<li style=\"direction: ltr; text-align: left;\">XRF<\/li>\n<li style=\"direction: ltr; text-align: left;\">XRD<\/li>\n<li style=\"direction: ltr; text-align: left;\">SEM\/EDS<\/li>\n<li style=\"direction: ltr; text-align: left;\">Particle-size distribution<\/li>\n<li style=\"direction: ltr; text-align: left;\">LOI<\/li>\n<li style=\"direction: ltr; text-align: left;\">Bulk density<\/li>\n<li style=\"direction: ltr; text-align: left;\">Apparent porosity<\/li>\n<li style=\"direction: ltr; text-align: left;\">Thermal-shock testing<\/li>\n<li style=\"direction: ltr; text-align: left;\">Corrosion testing<\/li>\n<\/ul>\n<h2 style=\"direction: ltr; text-align: left;\">Environmental Benefits: Life Cycle Assessment<\/h2>\n<p style=\"direction: ltr; text-align: left;\">Recycling should not be evaluated only from the perspective of technical performance. The environmental benefit must also be considered.<\/p>\n<ul>\n<li style=\"direction: ltr; text-align: left;\">For every 1 tonne (1,000 kg) of refractory waste diverted from disposal and subjected to recycling or reuse, approximately 530\u2013\u06f5\u06f4\u06f0 kg of CO\u2082-equivalent greenhouse gas emissions can be avoided.<\/li>\n<li style=\"direction: ltr; text-align: left;\">Producing virgin refractory raw materials often requires high-temperature processing. When a spent refractory is recycled, part of the energy already invested in producing the original refractory is retained.<\/li>\n<li style=\"direction: ltr; text-align: left;\">Recycling reduces: landfill demand, waste transportation, disposal costs, long-term accumulation of mineral waste. This is especially important because refractory waste is largely inorganic and can remain in landfills for very long periods.<\/li>\n<li style=\"direction: ltr; text-align: left;\">Replacing virgin raw materials with recycled refractory aggregates reduces the need for extraction. Consequently, recycling can reduce: land occupation, ecosystem disturbance, dust generation, water consumption, energy consumption.<\/li>\n<li style=\"direction: ltr; text-align: left;\">If recycled refractory waste is processed close to the steel, cement, glass or non-ferrous plant where it is generated, it can become a local secondary raw material.<\/li>\n<li style=\"direction: ltr; text-align: left;\">If the recycled material has appropriate properties, it can reduce the cost of virgin raw materials.<\/li>\n<\/ul>","protected":false},"excerpt":{"rendered":"<p>Introduction Refractory materials are indispensable components of high-temperature industrial processes, including iron and steelmaking, cement production, glass manufacturing, and non-ferrous metallurgy. These materials operate under severe thermal, mechanical, and chemical conditions and are consequently replaced after a certain period of service. The resulting spent refractory materials constitute a significant industrial waste stream. The conventional management [&hellip;]<\/p>\n","protected":false},"author":1001006,"featured_media":0,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[280],"tags":[],"class_list":["post-19127","post","type-post","status-publish","format-standard","hentry","category-280"],"yoast_head":"<!-- This site is optimized with the Yoast SEO Premium plugin v24.1 (Yoast SEO v28.2) - https:\/\/yoast.com\/product\/yoast-seo-premium-wordpress\/ -->\n<title>From Spent Refractories to High-Value Secondary Raw Materials - \u0641\u0631\u0622\u0648\u0631\u062f\u0647 \u0647\u0627\u06cc \u0646\u0633\u0648\u0632 \u0622\u0630\u0631\u0634\u0647\u0627\u0628 \u062a\u0628\u0631\u06cc\u0632<\/title>\n<meta name=\"description\" content=\"Spent refractories recycling converts refractory waste into high-value secondary raw materials, reducing landfill demand, virgin raw material consumption, energy use, and CO\u2082 emissions.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/azarshahab.com\/en\/spent-refractories-recycling\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"From Spent Refractories to High-Value Secondary Raw Materials\" \/>\n<meta property=\"og:description\" content=\"Spent refractories recycling converts refractory waste into high-value secondary raw materials, reducing landfill demand, virgin raw material consumption, energy use, and CO\u2082 emissions.\" \/>\n<meta property=\"og:url\" content=\"https:\/\/azarshahab.com\/en\/spent-refractories-recycling\/\" \/>\n<meta property=\"og:site_name\" content=\"\u0641\u0631\u0622\u0648\u0631\u062f\u0647 \u0647\u0627\u06cc \u0646\u0633\u0648\u0632 \u0622\u0630\u0631\u0634\u0647\u0627\u0628 \u062a\u0628\u0631\u06cc\u0632\" \/>\n<meta property=\"article:published_time\" content=\"2026-09-20T09:59:46+00:00\" \/>\n<meta property=\"article:modified_time\" content=\"2026-09-20T10:07:00+00:00\" \/>\n<meta property=\"og:image\" content=\"https:\/\/azarshahab.com\/wp-content\/uploads\/2023\/10\/Slider1.jpg\" \/>\n\t<meta property=\"og:image:width\" content=\"1599\" \/>\n\t<meta property=\"og:image:height\" content=\"898\" \/>\n\t<meta property=\"og:image:type\" content=\"image\/jpeg\" \/>\n<meta name=\"author\" content=\"root\" \/>\n<meta name=\"twitter:card\" content=\"summary_large_image\" \/>\n<meta name=\"twitter:label1\" content=\"Written by\" \/>\n\t<meta name=\"twitter:data1\" content=\"root\" \/>\n\t<meta name=\"twitter:label2\" content=\"Est. reading time\" \/>\n\t<meta name=\"twitter:data2\" content=\"5 minutes\" \/>\n<script type=\"application\/ld+json\" class=\"yoast-schema-graph\">{\"@context\":\"https:\\\/\\\/schema.org\",\"@graph\":[{\"@type\":\"Article\",\"@id\":\"https:\\\/\\\/azarshahab.com\\\/spent-refractories-recycling\\\/#article\",\"isPartOf\":{\"@id\":\"https:\\\/\\\/azarshahab.com\\\/spent-refractories-recycling\\\/\"},\"author\":{\"name\":\"root\",\"@id\":\"https:\\\/\\\/azarshahab.com\\\/#\\\/schema\\\/person\\\/bb86a4c800add770a791d93664c369d7\"},\"headline\":\"From Spent Refractories to High-Value Secondary Raw Materials\",\"datePublished\":\"2026-09-20T09:59:46+00:00\",\"dateModified\":\"2026-09-20T10:07:00+00:00\",\"mainEntityOfPage\":{\"@id\":\"https:\\\/\\\/azarshahab.com\\\/spent-refractories-recycling\\\/\"},\"wordCount\":782,\"publisher\":{\"@id\":\"https:\\\/\\\/azarshahab.com\\\/#organization\"},\"articleSection\":[\"\u0645\u0642\u0627\u0644\u0627\u062a\"],\"inLanguage\":\"en-US\"},{\"@type\":\"WebPage\",\"@id\":\"https:\\\/\\\/azarshahab.com\\\/spent-refractories-recycling\\\/\",\"url\":\"https:\\\/\\\/azarshahab.com\\\/spent-refractories-recycling\\\/\",\"name\":\"From Spent Refractories to High-Value Secondary Raw Materials - 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