A Thesis in the Making

The daily life of a PhD student is a beautiful cycle of reading literature, planning experiments, conducting said experiments, taking notes, reading more literature, analysing data, writing conclusions, proofreading, realising your conclusions make no sense, reading even more literature, questioning your life choices, asking your postdocs for help, bothering your professor, getting valid answers, rewriting everything, and finally… submitting your manuscript for internal review.

After you receive your first devastating review, you are usually back to questioning your life choices. But after convincing yourself that quitting is not an option and you’ve successfully deleted that fast food cashier application you had written out of pure desperation at 2 AM, you start over. The internal reviews pointed out the weak spots in my manuscript. In addition to the red thread not being clearly recognisable and well-structured, my scientific English showed room for improvement. Don’t get me wrong, it wasn’t awful (or so they said), but it wasn’t as precise and clear as it should have been.

Now, I thought my English was solid. I’ve taken English lectures, English exams, and I watch all my media in English, so surely, writing a paper wouldn’t be that bad, right? Wrong. Scientific English is a different beast.

After the whole writing, internal reviewing, rewriting, and questioning your life choices process, you finally end up with your first manuscript submission. Clicking the submit button felt like sending my soul into the void. This submission was not just a milestone but an essential step, as my doctoral thesis depends on at least three published papers, supplemented by a comprehensive text that integrates and contextualizes them. No publications, no thesis!

A few days later, I got an email: “Your manuscript is under review.” Nice. The provided tracking link became my most-visited website. Then, at the end of November, the moment of truth arrived — the reviewers’ comments.

To my surprise, they were… actually quite nice? I had braced myself for soul-crushing criticism. But instead, the comments were constructive and even encouraging. I had one month to address the feedback, so I tackled every point carefully — either making the necessary changes or (politely) justifying why something couldn’t be changed.

A few days after resubmitting, the acceptance email arrived. And now I’m just happy to share my work with everyone, unsolicited:

https://www.sciencedirect.com/science/article/pii/S0921344925000370

I know that I’m in no position to give any advice, as I’m just a PhD student who was fortunate that my first publication went relatively smoothly. However, when I look around, I see my fellow PhD colleagues facing challenges similar to mine.

True to the saying, “There is nothing new under the sun” (Ecclesiastes 1:9), I would like to share my experiences:

Be patient, be persistent, and stay open to feedback. Turning research into a clear and well-structured manuscript is an art—one that cannot be mastered overnight.

This year’s ReSoURCE project review meeting was hosted in Vienna by RHI Magnesita, marking a significant milestone for our consortium. For many of our partners, as well as our project officer and the technical expert, it was the first time visiting our facilities in our headquarters. 

The two-day meeting began on Tuesday morning with a full agenda. Each partner leading a work package had the opportunity to present the progress of their respective work packages with the support of all the other partners involved while fostering valuable discussions and knowledge exchange. We concluded the day with a networking dinner, where we enjoyed delicious Austrian cuisine- a perfect setting for informal discussions and strengthening collaborations. 

The highlight of the visit – and the entire review meeting – was seeing the RAPTOR in action. While many of us had previously seen images of the cutting-edge automated sorting machine, witnessing it operate in real life was an entirely different experience. Our colleagues from LSA and RHI Magnesita guided us through the machine’s interior, explaining each station in detail and demonstrating the LIBS (Laser-Induced Breakdown Spectroscopy) technology in action. NEO and ILT could present their related work regarding HSI (hyperspectral imaging) and integration of the multi-sensor setup. 

The visit was undoubtedly a key moment of our meeting, sparking engaging discussions and reinforcing the importance of innovation in refractory recycling. The entire gathering was filled with knowledge sharing, hands-on experiences, and valuable exchanges – making a truly successful event for the ReSoURCE project.

After completing the one-year mechanical assembly phase of the ReSoURCE sorting system Demo A (a.k.a the Raptor), we are proud to announce that the plant has successfully completed its 1,000 km journey and has now arrived at its new home at RHI Magnesita- Mireco in Mitterdorf (St. Barbara im Mürztal), Austria.

We are pleased with the smooth transport process and the efficient assembly on-site, which reflects the meticulous planning and coordination of the past weeks. The entire system was transported using three trucks: two trucks carried one container each, along with the connecting bridge, while a third truck transported smaller components, and the tools required for assembly.

At its destination in the picturesque Mürztal region, the two containers and the connecting module were unloaded sequentially using a 100-ton crane. Subsequently, assembly work began on the individual components, which had been packed for transport. Among others, these included the material intake hopper mounted on Container 1, the external piping for the air extraction and filtration system, and the conveyor belt located between the containers. This was specifically designed to fold for transport and therefore was unfolded and installed during the assembly process.

The essential assembly of the 36-ton sorting system, housed in two 40-foot shipping containers, was completed within just one workweek. We extend our gratitude to RHI Magnesita for their thorough preparation of the installation site and for actively supporting our engineers and technicians from LSA GmbH on-site. The system has successfully passed its first validation, handling wind, weather, and the harsh temperatures of the Austrian winter without issue.

The current focus is on the training of future RHI Magnesita’s operating personnel, as well as further fine-tuning of the software. Our experts are on-site to provide comprehensive guidance on process workflows and system operation, ensuring the plant is ready to begin its new chapter in Austria.

We are looking forward to utilizing the insights gained during the commissioning phase in Austria to further optimize the system and refine its processes across all modules. The successful transport and installation of the plant mark an important step towards the sustainable and economically efficient reuse of recycled refractory materials.

Together with RHI Magnesita and our project partners, we are excited to drive the future of recycling to the next level!

From 13 – 15 November, the largest German-speaking waste management conference in Europe was held at the Montanuniversitaet Leoben. The event was organised by the Chair of Waste Processing Technology and Waste Management at the Montanuniversitaet Leoben and takes place every two years at the beginning of November. This prestigious gathering brought together participants from academia and industry to discuss cutting-edge topics in waste management and technology. The 2024 conference focused on key areas such as circular economy, sensor-based sorting including robotics, artificial intelligence, and eco-design. Other highlights included case studies, best practices, and discussions on mineral waste, industrial residues, and climate protection. A total of 752 attendees enjoyed 163 presentations organized into five parallel sessions over the course of the three-day event.

Of course, our ReSoURCE project was also represented and was already mentioned on the first day in the plenary lecture by Univ.-Prof. Dipl.-Ing. Dr.mont. Roland Pomberger. On Thursday evening, the project was featured in a detailed presentation titled “The heat is on!” which discussed the journey from material characterization to sensor training based on insights obtained during the project. Additionally, on the final day, participants learned about the practical applications of the lasers developed by LSA, with a focus on the sorting unit created as part of the ReSoURCE initiative.

Picture 1:  Alexander Leitner and Florian Feucht presenting project ReSoURCE.

I would like to take this opportunity to thank Alexander Leitner and Simone Neuhold once again: I really enjoyed working with you on the presentation as well as presenting it together.

One of the most anticipated sessions of the conference is the ‘Leoben Waste Debate’, where a specific topic sparks lively discussion among experts. This year, the debate centered on the question, “Secondary raw materials need rights: Are end-of-waste regulations THE solution for an intelligent circular economy?” This engaging one-hour discussion took place at the end of the first day, providing a thought-provoking conclusion to the first day.

Picture 2: Leoben Waste Debate

Three conference days full of exciting presentations later, I can summarise the Recy DepoTech 2024 as a very successful event, both as a visitor and as part of the organisation team.

Will visit again, so see you at Recy DepoTech 2026!

Picture 3: Organization Team behind Recy DepoTech

Photo credits: © Chair of Waste Processing Technology and Waste Management of  Montanuniversitaet Leoben.

A Global Leader in R&D of Cutting-edge Laser Technology

For 40 years, the Fraunhofer ILT has stood for exceptional expertise in the field of laser technology. Since its formation in 1985, the Aachen-based research institute has become one of the world’s top addresses for laser research and development, as well as for the transfer of new laser processes into real-world applications. The spectrum ranges from the development of innovative laser beam sources with customized spatial, temporal, and spectral properties and output powers to the development of specific solutions for beam shaping and beam guiding, frequency conversion, as well as design, layout and packaging of optical components. In addition, there is outstanding expertise in the field of digitalization, with broad application of AI and a high level of competence in software development.

Growing Impact on Sustainability and Efficient Use of Resources

On this basis, more than 550 highly specialized employees are shaping the transfer of cutting-edge technology approaches into seven technology fields which are Measurement Technology, Additive Manufacturing, Surface Technology, Joining, Cutting, EUV and Plasma Technology and Medical Technology. As highly precise, contact-free and massless tools, lasers have a constantly growing impact on modern industrial production, medicine and research, and also in electronics and semiconductor development. The Fraunhofer ILT is making this enabling role of photonics accessible to five markets in particular: Energy, Automotive, Aerospace, Microelectronics as well as Medical Technology and Health. But the range of applications is increasing: in environmental and recycling technologies, water treatment, in sustainable agriculture, for climate and weather monitoring from space or for the laser-ignited inertial confinement fusion as a climate-neutral energy source of the future, the laser technologies developed in Aachen are major trailblazers.

Core Task: Knowledge Transfer

Under one roof, the Fraunhofer Institute for Laser Technology ILT offers R&D, system design and quality assurance, consultation and education. Numerous industrial laser systems from various manufacturers and extensive infrastructure are available for R&D-work. In the adjacent Digital Photonic Production DPP research campus, companies cooperating with Fraunhofer ILT work in their own laboratories and offices. The basis for this special form of technology transfer is a long-term cooperation agreement with the institute. Benefits include the use of the technical infrastructure and the exchange of information with local experts. In addition to established laser manufacturers and innovative laser users, also start-ups from the fields of special plant engineering, laser manufacturing technology and laser measurement technology find a suitable environment here for the industrial implementation of their ideas. Another form of know-how transfer: More than 40 spin-offs have been established from the Fraunhofer ILT, all of which have successfully established themselves in their markets.

A top research organization at its back

Fraunhofer ILT is integrated into the Fraunhofer-Gesellschaft, which is one of the leading research institutions in Germany with currently 76 institutes and research units. Founded in 1949 the Fraunhofer-Gesellschaft has nearly 32,000 employees, predominantly scientists and engineers, and an annual business volume of 3.4 billion euros. It plays a crucial role in the innovation process by prioritizing research in key future technologies and transferring its research findings to industry to strengthen Germany as a hub of industrial activity and for the benefit of society. For more information, please visit https://www.ilt.fraunhofer.de/en.html and the Fraunhofer-Gesellschaft’s websites at https://www.fraunhofer.de/en.html.

The first Factory Acceptance Test (FAT) of Demo A was nothing short of thrilling. This was the moment we’d been working towards for so long—years of hard work and dedication finally becoming reality. Watching the key components—singularization, LIBS, robotic gripping, and air ejection—working together in real-time, we couldn’t help but feel proud. It’s not just a machine; it’s a symbol of how far we’ve come, and it gave us a powerful glimpse of the future we’re building. To share some of these impressions, it’s best to have a quick look at this short video:

First impressions of Demo A: Cutting-Edge Sorting Equipment for Refractory Recycling

While singularization showed promising results, there’s still some fine-tuning ahead to perfect particle separation. The LIBS system also delivered encouraging data, with spectra aligning well with our calibration, though we know there’s more precision to unlock. And while the system’s overall speed can still improve, we’re confident that these are small hurdles we’ll overcome in the next optimization phase. With the progress we’ve made so far, the path ahead looks bright, and we’re excited to push Demo A to its full potential.

A big part of this progress is thanks to the relentless efforts of our partners at LSA. They’ve been pushing the system to its limits, spending every available minute refining the equipment together with their suppliers. Their dedication and passion for this project are truly inspiring, and it’s great to have such committed partners in this journey. As the coordinator, RHI Magnesita is excited to see how the team is pouring their energy into finishing Demo A.

Looking ahead, we’ll be focusing on fine-tuning the system to ensure optimal performance across all units. Once those adjustments are made, we’ll move forward with demounting and shipping Demo A for further validation. While there’s more work ahead, we’re feeling optimistic about the progress so far, and it’s exciting to see the pieces coming together.

Stay tuned as we continue pushing forward toward the full-scale realization. The delivery to Austria is just around the corner, bringing us one step closer to the next exciting chapter for Demo A.

One year ago, in October 2023, our project partner NEO installed a Hyper Spectral Imaging (HSI) system in Leoben and provided us with training to generate a substantial dataset—a quite large dataset of over 150 GB—aimed at developing a classification model to support LIBS measurements for sorting our spent refractories.

This HSI system consists of a high resolution optical sensor operating in the 400-2500 nm range. It can be used to detect and differentiate materials based on their unique spectral signatures, which are influenced by mineralogy and bonding systems. The HSI sensor supports the LIBS unit in two primary ways:

1. Identifying Key Regions: It locates areas on the sample that are significant for classification, such as regions that are free from contamination.
2. Material Classification: It classifies spent refractories, thereby improving accuracy and validating classification decisions.

To achieve effective classification, the system must be trained using samples with known properties, referred to as ground truth data. This data serves as a benchmark for training multivariate and machine learning models. In the context of optical sensors, these samples are typically prepared under controlled conditions, ensuring that their spectral properties are well-documented and reliably reproducible. Ground truth data is crucial for training algorithms, as it provides a reference for the model to learn how to recognize patterns. However, as you might recall from previous blog posts, determining the exact material properties of spent refractories poses certain challenges. Fortunately, we recognized the importance of sampling early in the project and gained valuable insights into our feedstock, enabling us to provide well-characterized samples for our initial training.

For our sample preparation, we selected spent refractory samples from various customers and aggregates corresponding to specific sorting classes including defined common contaminants. We identified these classes either visually through well-known optical features or by chemically analyzing the bricks for confirmation. We then manually crushed the samples to ensure their integrity, ultimately providing images and data for about 2,000 pieces representing the sample shape to be placed on the conveyor belt in the sorting equipment.

Once prepared, these samples were analyzed using HSI. For data acquisition, each sample was illuminated, and the resulting spectral data was recorded as a reflectance spectrum. Consistency in data collection and meticulous documentation was crucial, so in total, we stored the aforementioned 150 GB of spectral data, along with an additional 4.5 GB of images documenting the sample origins, setup, and measurement settings.

After gathering the spectral data, we shared it with NEO to extract relevant features for classification. This process may involve statistical analyses or dimensionality reduction techniques, such as Principal Component Analysis (PCA), to pinpoint the most informative aspects of the spectral data. To aid in this, we also provided spectral data for our most common raw materials, helping to link spectral features to material classifications.

With the ground truth data and extracted features, we began the actual model training. By applying machine learning algorithms, such as Support Vector Machines (SVM), the model learns to associate specific spectral patterns with their corresponding material classifications. The final step involves validating and testing the model to ensure its effectiveness. This validation process requires a separate set of samples not included in the training phase, which assesses the model’s ability to generalize to new, unseen data—an essential measure of its practical applicability.

A year after the installation of the equipment and continuous exchange with NEO, we are pleased to report that we can classify certain sorting classes with an accuracy exceeding 95%. While fine-tuning remains necessary and the upscaling to actual equipment is still in progress, we are excited about the advancements made in our material classification capabilities. By focusing on chemical and mineralogical properties rather than visual features, we are not only minimizing subjectivity in our sorting process but we are also able to customize our sorting classes to further valorize our circular raw materials.

About CPI

CPI accelerates the development, scale-up, and commercialization of innovations in smart AgriFoodTech, energy storage, HealthTech, materials and pharma, while also catalyzing the adoption of advanced technologies and manufacturing solutions. These efforst aim to benefit people, communities, and the planet.  Through incredible innovation experts and infrastructure, experts at CPI look beyond the obvious to transform healthcare and drive towards a sustainable future.

As a trusted partner of industry, academia, government, entrepreneurs, and the investment community, CPI connects the dots within the innovation ecosystem to make great ideas and inventions a reality. Being part of the High Value Manufacturing Catapult, they facilitate access to world-class organisations to deliver transformation across industries and landscapes.

From the North of England and Scotland, CPI invests in people and disruptive technologies to invigorate economies, create circular supply chains and make our world a better place.

CPI Today

As of 2024, CPI has hit its 20-year milestone. Twenty years of innovation and impact, shaping the economy of the future with ground-breaking technologies.  It started with a clear strategy to leverage the UK’s knowledge and skills to ensure the economy remained competitive in the growing global marketplace.

Now with nearly 800 employees, CPI celebrates its growth as one of the leading influences on innovation in the UK. The organisation plays a crucial role in enabling the manufacturing sector, building national resilience, addressing health and well-being challenges, and supporting ambitious sustainability targets.

Through dedicated people and valued partners, the organisation has collaboratively transformed challenging scientific concepts into commercially viable products, unlocking almost £3bn in private investment.  CPI has a 60% SME customer base and is helping to transform industrial landscapes in the North East and beyond.

The best thing about innovation is that it never stands still, and CPI’s mission is not over. Innovation has been at the core of their work for the past twenty years and will remain the driving force for many years to come. If you are interested in knowing more, please visit www.uk-cpi.com.

The International Conference on Conveying and Handling of Particulate Solids (CHoPS) is widely regarded as one of the premier international forums for professionals in academia and industry to exchange ideas, share knowledge, and collaborate on innovations in the field of particulate solids handling and processing. CHoPS brings together experts who focus on the efficient handling of powders and particulate materials, fostering collaboration and sparking breakthroughs that advance industrial processes worldwide.

This year, as the 11^th edition of the CHoPS series, CHoPS 2024 took place at the Edinburgh International Conference Centre (EICC), from September 2^nd to 4^th, 2024, hosted by the University of Edinburgh in collaboration with an international organizing committee of industry leaders and experts. Over the course of three days, the event continued the success of previous years, offering an excellent platform for researchers and professionals to present innovative discoveries, discuss the latest industry challenges, and develop global partnerships.

The SINTEF research team, representing the ReSoURCE project produced an abstract, titled ‘Enhancing Recycling Efficiency of Residual Refractory Materials: Experimental Methods and Fine Particle Classification Techniques,’ which was selected for a full oral presentation. The presentation addressed the challenges of recycling residual refractory materials, particularly the finer particles (less than 5mm), which present unique difficulties for both environmental and industrial health due to their small size and potential to release dust.

Recycling efficiency is critical to the successful implementation of circular economy principles. However, the behavior of fine particles during recycling processes poses a significant barrier to fully utilizing reclaimed materials as secondary raw materials. This challenge is particularly pronounced in the refractory industry, where fine residues are often difficult to separate and reuse.

In their presentation, the SINTEF team emphasized the need to enhance fine particle classification methods to overcome this limitation. The talk focused on experimental approaches that highlighted innovative air-assisted classification techniques, including crossflow air classifiers and multi-chamber fluidized bed classifiers. These methods, which utilize differences in particle size and density, have shown promising results in enhancing material recovery efficiency.

The methodologies discussed in the presentation showcased the potential of direct sorting techniques to increase material recovery rates, significantly contributing to sustainable industrial practices. The audience responded enthusiastically to the team’s findings, recognizing their applicability not only to the recycling of refractory materials but also to other industries facing similar challenges with fine particle processing.

The presentation sparked a dynamic follow-up discussion on how the techniques developed within the ReSoURCE project could be adapted across multiple sectors, such as construction, mineral processing, and other industrial fields. This exchange of ideas underscored the value of multidisciplinary collaboration in developing solutions that can have broad applications, advancing the vision of a circular economy and sustainable resource management.

A  Global Leader in Refractory Solutions 

RHI Magnesita stands as a world-leading provider of refractory products and services, which are essential for industries operating at high temperatures, such as steelmaking, cement production, non-ferrous metals, and glass manufacturing. These industries require specialized materials that can withstand extreme temperatures, often exceeding 1,200°C, to protect equipment, enhance efficiency, and maintain safety in high-heat environments.

With headquarters in Vienna, Austria, RHI Magnesita has a broad global reach. The company serves as a crucial partner to industrial clients across five continents, offering not only high-quality refractory materials but also comprehensive solutions that span from mining to recycling. RHI Magnesita’s vertically integrated business model ensures control over the entire value chain, from the extraction of raw materials to the development and delivery of advanced refractory products.

A Powerful Merger

In 2017, RHI Magnesita was formed through the merger of RHI AG, an Austrian company with strong European roots, and Magnesita Refratários, a Brazilian company with a significant presence in Latin America. The merger combined the strengths of both companies, creating a global leader with unmatched expertise and resources. This strategic combination allowed the new entity to leverage its diversified geographic footprint, technological leadership, and comprehensive product portfolio to better serve a variety of industries worldwide.

The integration of the two companies also enhanced RHI Magnesita’s research and development (R&D) capabilities, positioning it as a leader in innovation within the refractory sector. The company invests heavily in R&D to continuously improve the performance and lifespan of its products, while also reducing their environmental impact. This commitment to innovation enables RHI Magnesita to remain at the forefront of the industry, setting new standards for high-temperature materials and processes.

Innovation and Sustainability

As a global industry leader, RHI Magnesita prioritizes sustainability in its operations and product development. The company is focused on reducing its environmental footprint through initiatives such as the development of refractory products containing circular raw materials. One of its key goals is to enhance the recycling of used refractory products, thereby minimizing waste and conserving resources.

RHI Magnesita’s sustainability strategy is also aligned with the broader global push towards reducing carbon emissions. The company is actively working to improve the energy efficiency of its production processes and reduce CO2 emissions across its operations. By promoting responsible resource management and developing innovative solutions, RHI Magnesita is well-positioned to support its customers in their own sustainability efforts.

Global Presence and Expertise

RHI Magnesita operates over 47 production sites and 8 recycling facilities globally, along with more than 70 sales offices, ensuring that it can serve customers efficiently wherever they are located. The company’s diverse geographic footprint allows it to meet the specific needs of regional markets while maintaining the highest international standards for quality and performance.

With a workforce of  20,000 employees, RHI Magnesita draws on its extensive global expertise to deliver solutions tailored to the unique challenges of each industry it serves. The company’s comprehensive service offering extends beyond products to include technical support, performance optimization, and long-term maintenance strategies for its customers.

RHI Magnesita is more than just a refractory supplier—it is a global partner dedicated to innovation, sustainability, and customer success. By leveraging its expansive global footprint, cutting-edge technology, and commitment to sustainability, RHI Magnesita continues to lead the way in high-temperature industrial solutions, ensuring safety, efficiency, and performance for industries around the world. For more information, please visit rhimagnesita.com and to keep up with the latest innovations and industry insights, join RHI Magnesita’s LinkedIn community