On June 26, 2025 the webinar titled “Unlocking Circular Potential: Refractory Fillers in Advanced Composites” was organized by the ReSoURCE project in collaboration with RHI Magnesita, CPI, and Crowdhelix. Materials scientists, business representatives, and innovators convened virtually to talk about how recycled refractory materials might provide high-performance, environmentally friendly solutions for the composites industry.  

Alexander Leitner, ReSoURCE Project Coordinator at RHI Magnesita, opened the webinar by outlining the goal of the project and described how the project is using automated, sensor-based sorting technologies that integrate Artificial Intelligence (AI), Hyperspectral Imaging (HSI), and Laser-Induced Breakdown Spectroscopy (LIBS) to address the challenges associated with recycling refractory. 

The technological development of the project’s two recycled filler products, mRefCem and mRefFerro, was thoroughly examined by Ananda Roy, Yugal Rai, and Jack Maxfield from CPI. They shared information on the products’ physical characteristics, processing techniques, and performance in various applications. Part of the conversation was mediated by Claire Defty (CPI), who also pointed out possible avenues for industry adoption. The Circular Industry Helix, a platform created to link researchers, businesses, and innovators interested in using these materials at scale, was presented by the last speaker, Cais Jurgens from Crowdhelix. 

CPI Team presented the material passports (mRefCem and mRefFerro) encompassing particle size distributions, densities, thermal and dielectric properties, and thermogravimetric profiles. In order to increase compatibility with different polymer systems, they also talked about surface modification techniques that use silanes (GLYMO, APTES). 

The results of application testing were impressive: Epoxy composites improve fire resistance by reducing peak heat release and extending ignite periods in comparison to unfilled resin. Thermoplastic composites: mRefFerro provided remarkable stiffness and thermal stability in virgin HDPE, PP, and recycled PP, while mRefCem provided a well-balanced combination of strength and flexibility. Both performed on par with or better than conventional CaCO3 fillers. Better print quality, adhesion, and dispersibility are achieved with dielectric inks, opening the door for environmentally friendly printed electronics applications. 

Impact on the Environment and the Market 

About 1.5 tons of CO₂ can be saved per tonne of recycled refractories when they are used instead of virgin raw materials. Environmental Product Declarations (EPDs) and Life Cycle Assessments (LCAs) are being used by industry partners to quantify these savings and show consumers the environmental benefits. 

It can be concluded from the webinar that the ReSoURCE Project’s strategy is progressing from concept to solutions that are ready for the market. The research is proving that recycled refractories may perform better than traditional fillers in terms of sustainability and performance parameters, as the mobile, AI-driven LIBS/HSI sorting system approaches maturity and shows promising application results in thermosets, thermoplastics, and dielectric inks.  

During the Q&A, industry participants expressed interest in supply-chain integration and pilot trials, especially in the electronics, automotive, and construction sectors. In order to speed up industrial adoption, the following phase will concentrate on finalizing LCAs and EPDs, scaling manufacturing, and strengthening cooperation through the Circular Industry Helix. 

Next Steps 

The main takeaway of the event was a noticeable change in viewpoint: spent refractories should be seen as a valuable secondary resource with substantial commercial and environmental potential rather than as an expensive industrial waste stream that is headed for landfills. These materials can be converted into high-performance fillers that meet or surpass the technical requirements of virgin alternatives by implementing sophisticated, mobile sorting systems that integrate LIBS, HSI, and AI, along with focused material processing and application-specific development. In addition to lowering dependency on basic raw materials and related CO₂ emissions, this creates prospects for their application in a variety of industries, including infrastructure, automotive, electronics, and sustainable manufacturing.  In addition, Cais Jurgens from Crowdhelix concluded by inviting participants to become a part of the Circular Industry Helix and take part in co-development projects; The platform allows businesses, researchers, and innovators to explore collaborative research projects, pilot studies, and co-development projects that expedite the use of recycled refractories and integrate the concepts of the circular economy into industrial supply chains. 

If you are interested in learning more, watch the webinar recording available in our YouTube channel:

Webinar Recording: Unlocking Circular Potential: Refractory Fillers in advanced Composites