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The European Green Deal demands for profound industrial sustainability and circularity solutions within the steel sector (leading consumer of refractory materials). In the framework of the EU funded CESAREF(1) consortium, my study deals with tundish refractory lining materials. They are indispensable for continuous steel casting, representing an important leverage due to their significant waste generation and challenging operational requirements. My research integrates the characterization of cutting-edge industrial refractory products with an integrated strategy to elaborate a rigorous (and versatile) predictive and prescriptive framework. The final goal is to maximize both operational lifetime and end-of-life refractories value (2).

The cornerstone of this project is the synergy between numerical methods and experimental investigation (Figure 1). In order to understand critical thermomechanical stresses distribution and material degradation pathways, Finite Element Analysis (FEA) is exploited. In parallel, the experimental validation involves pre- and post-mortem characterization of pivotal refractory systems, such as MgO-based working linings, aluminosilicate castable safety linings and vermiculite-forsterite insulation linings. This rich numerical and empirical dataset then fuels two decision-support techniques: Failure Mode, Effects, and Criticality Analysis (FMECA) and Multi-Criteria Decision Methods (MCDM).

Focusing on refractories reusability, we tailor FMECA protocols developing criticality and severity algorithms that quantitatively correlate the in-service evolution of crucial material properties for a holistic evaluation of degradation mechanisms. Thermal conductivity, porosity, elastic modulus, and crack propagation are some of the key properties which change is assessed in relation with the operational conditions. This methodology provides a scientifically robust foundation for confidently extending tundish refractory lining campaigns.(3)

Furthermore, to unlock high-value, closed-loop recycling, our research leverages also MCDM tools like TOPSIS (Technique for Order of Preference by Similarity to Ideal Solution) through a spectrum of criteria: intrinsic attributes (e.g., purity, deleterious phases presence), operative performance (e.g., corrosion rate, permeability) environmental and economic parameters (carbon footprint, production energy, and production costs). Our investigations reveal, for instance, that judicious incorporation of quality-assured Secondary Raw Material (SRM), potentially in the range of 20-50% for specific formulations, can present an optimal balance, heavily guided by the proper refractory design and the strategic priorities.

Finally, this research project integrated a powerful and versatile data-driven toolkit applied to multicomponent system such as the refractory linings for tundish in steel industry. It empowers a paradigm shift from traditional, often empirical, refractory management to a predictive and prescriptive science. Furthermore, the approach aims in resource optimization and valorization, waste reduction, and environmental impact reduction, by carving a clear and actionable pathway towards a true circular closed-loop system for these indispensable ceramic materials.

Andrea SALERNO

PhD student

University of Limoges, IRCER, Limoges, France - Vesuvius group plc, Department of Advanced Refractories, Ghlin, Belgium

andrea.salerno@unilim.fr

linkedin.com/in/andrea-salerno-726919168

Links:

1. https://www.cesaref.eu/

2. Insights on numerical models to predict potential recyclability of spent refractories from steel making industry

3. Coupled numerical simulation and post-mortem analysis to evaluate tundish lining refractories lifetime