19AUGUST 2025Artificial Intelligence has now become an effective tool to foster deeper understanding of the correlation between identification of wear influencing parameters and refractory benchmarking for the development of a predictive wear model which can forecast a refractory failure with high level of accuracymaterials are not compromised. For instance, bio-based binders have shown promising results in maintaining the mechanical strength and thermal stability required for high-performance refractory applications. Similarly, the use of secondary raw materials has been effective in producing refractories that meet the stringent demands of steel and cement production processes.Furthermore, the integration of these sustainable materials into refractory production aligns with global sustainability goals and regulatory requirements, making them a viable solution for industries looking to reduce their environmental impact.With rising energy costs, how are advanced refractory coatings and nano-structured materials improving thermal efficiency and reducing fuel consumption in kilns and furnaces?Advanced refractory coatings and nano-structured materials are designed to enhance the performance and sustainability of industrial processes.Advanced refractory coatings and nano-structured materials are being developed to improve thermal efficiency and reduce fuel consumption in kilns and furnaces. These materials offer superior heat resistance and thermal insulation, which helps in minimizing heat loss & optimizing energy usage.Recent advances in refractory coatings, including the development of nanocoatings, provide new standards of performance and sustainability across multiple industries. These coatings, composed of nanoparticles, offer superior heat resistance and thermal insulation, resulting in a significant reduction in energy consumption by effectively minimizing heat loss. Additionally, the introduction of self-healing refractory coatings, which can automatically repair cracks and damage, maintains their protective capabilities without human intervention. This self-healing mechanism is activated by the heat to which the refractories are exposed, providing continuous protection even under the most corrosive conditions.Nanotechnology in refractory coatings has emerged as a revolution, significantly transforming thermal resistance and the durability of materials used in high-temperature environments. The incorporation of conductive nanomaterials into refractory coatings improves thermal conductivity, facilitating the rapid dissipation of heat generated in high-temperature environments. This enhanced thermal efficiency contributes to optimal performance in industrial applications.Given India's limited refractory recycling infrastructure, what scalable solutions are emerging to improve circularity and reduce landfill waste from spent refractories?Given India's limited refractory recycling infrastructure, several scalable solutions are emerging to improve circularity and reduce landfill waste from spent refractories. These solutions focus on enhancing the recycling process and promoting sustainable practices within the industry.One of the key approaches is the adoption of a circular economy model, which involves collaboration with recycling firms to recover spent refractories from industries like steel, cement, glass, and petrochemicals. These firms are equipped with state-of-the-art facilities that sort, clean, crush, wash, screen, and package the materials for reuse. The recycled refractories meet stringent quality standards, exhibiting properties like high refractoriness, thermal shock resistance, and chemical stability. Additionally, researchers are exploring novel techniques for reclaiming refractories, extending their lifespan, and minimizing waste.Innovative solutions under development include sorting during or after dismantling, the removal or stabilization of contaminants, and fragmentation methods to increase mineral
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