Every year, millions of tonnes of high-performance materials—refractories—are used in industries like steelmaking, cement production, and glass manufacturing. These materials withstand extreme heat and stress, lining furnaces, kilns, and reactors to keep industrial processes running. But what happens after they’ve done their job? 

Too often, spent refractories end up in landfills or downcycling applications. That’s not only wasteful, it’s a missed opportunity. Many of these materials still have valuable properties and can be recycled, —if we can sort and process them effectively. That’s where new technology is stepping in. 

Figure 1. Overview of manual recycling processing steps.

From Manual to Machine: A Recycling Revolution 

Until recently, sorting used refractory bricks was a manual process. Workers can only handle large chunks (over 80 mm), and decisions are mainly based on visual inspection. It works, but is lacking in efficiency especially in a world where circularity and carbon reduction are urgent goals which need to be achieved quickly. 

Now, a new generation of automated sensor-based sorting systems is up to make a big difference. These high-tech machines will handle much smaller particles (as small as 5 mm), sort them faster, and—most importantly—analyze their chemical composition in real time. 

Using tools like Laser-Induced Breakdown Spectroscopy (LIBS) and Hyperspectral Imaging (HSI), these systems  analyze each piece of material for its chemical and mineral content. That means recyclers can identify exactly what each particle is made of and separate it accordingly—resulting in higher-quality recycled materials. 

A Game-Changer for Circularity 

Why does this matter? Because better sorting means better recycling. When materials are accurately identified and separated, they can be reused in new refractory products without compromising performance. That reduces demand for virgin raw materials, saves energy, cuts carbon emissions, and keeps valuable resources in use. 

RHI Magnesita, one of the world’s leading refractory producers, is pioneering this approach with support from the ReSoURCE project. Together with industry and research partners, the company is developing mobile sorting units—container-sized systems that can be deployed directly at customer sites. These units can process a couple of tonnes  of used refractories per hour, making recycling more convenient, more economical, and more sustainable. 

Building the Future, Brick by Brick 

This kind of innovation is essential if we’re serious about creating a circular economy. By combining cutting-edge science with practical engineering, the refractory industry is rethinking waste—and finding new value in old materials. 

At ReSoURCE, we believe that progress like this doesn’t just benefit industry —it benefits all of us. A smarter recycling system means a healthier planet, a more resilient supply chain, and a more responsible approach to the materials we depend on every day. 

If you’re interested in the technical foundations behind this approach, you can read the full article published in RHI Magnesita’s Bulletin 2024 here.