Sustainable Refractories: Innovations Driving a Greener Steel and Cement Industry

Prasant Kumar Naik, Managing Director of TRL Krosaki Refractories Ltd, in an interaction with Industry Outlook, discusses how India’s refractory manufacturers are embracing innovations such as bio-based binders, AI-driven predictive analytics, nano-materials, and circular economy practices to reduce carbon emissions, enhance performance, and support sustainable, cost-effective operations in the steel and cement industries. With over three decades of industry experience, Naik brings strong business acumen and expertise in operations, procurement, strategic sourcing, and energy management, having held key leadership roles across production, marketing, sales, and risk management.

With stricter carbon regulations in India, how are refractory manufacturers innovating to reduce emissions while maintaining high-performance standards in steel and cement production?

Refractory manufacturers in India are actively innovating to reduce emissions while maintaining high-performance standards in steel and cement production. One of the key strategies involves the use of bio-based binders and secondary raw materials, which help in reducing the carbon footprint while maintaining durability in steel and cement refractories. Additionally, advanced refractory coatings and nano-structured materials are being developed to improve thermal efficiency and reduce fuel consumption in kilns and furnaces.

Another significant innovation is the adoption of AI-driven predictive analytics, which optimizes refractory lifespan, reduces downtime, and ensures consistent performance in steel and cement plants. Furthermore, scalable solutions are emerging to improve circularity and reduce landfill waste from spent refractories, addressing the limited recycling infrastructure in India.

As sustainability pressures rise, how are innovations like bio-based binders and secondary raw materials reducing the carbon footprint while maintaining durability in steel and cement refractories?

Bio-based binders and secondary raw materials help in lowering emissions by replacing traditional, carbon-intensive binders with more sustainable alternatives. Bio-based binders, derived from renewable resources such as vegetable oils and lignin, offer a significant reduction in greenhouse gas emissions compared to conventional petroleum-based binders. Additionally, secondary raw materials, which include recycled and by-product materials, contribute to a circular economy by reducing the need for virgin raw materials and minimizing waste.

In the context of steel and cement refractories, these innovations ensure that the performance and durability of the materials 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 and 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 circularity. These technological developments provide customers with a low carbon footprint refractory product portfolio that offers high performance at competitive costs. Furthermore, responsible sourcing and waste management practices are being emphasized to align with global sustainability goals. Advanced processing techniques allow for the recovery of valuable minerals, converting waste into a resource.

How are AI-driven predictive analytics optimizing refractory lifespan, reducing downtime, and ensuring consistent thermal performance in steel and cement plants?

AI-driven predictive analytics leverage vast amounts of data collected from various operational processes to predict the wear and tear of refractory materials accurately. By analyzing process parameters and identifying patterns, AI models can forecast the optimal time for maintenance, thereby extending the lifespan of refractories.

In steel and cement plants, AI-driven predictive analytics help in maintaining consistent thermal performance by continuously monitoring the condition of refractory linings. This real-time monitoring allows for timely interventions, reducing the risk of refractory failure and minimizing downtime. Additionally, the use of AI in predictive maintenance ensures that the refractories are utilized to their maximum potential, reducing the need for frequent replacements and contributing to cost savings.

Furthermore, AI-driven analytics enable the optimization of furnace operations by adjusting process parameters to achieve optimal thermal efficiency. This not only enhances the performance of the refractories but also reduces fuel consumption and emissions, aligning with sustainability goals.

In modern steel plants, which have to be focused more and more on reliable operation planning to fulfill production plans without unexpected shutdowns and unplanned downtimes of the critical production facilities and assets, refractory life prediction along with integrated maintenance planning are of paramount importance due to following reasons;

• Maximize day-to-day heat planning with 100% safe operation.
• Planning of combined shutdowns of critical facilities
• Improvement of refractory cost/performance ratio and decrease of refractory consumption along with higher productivity

Artificial 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 accuracy. Input data of Residual thickness at various lifespan of a campaign, wear relevant data, lining quality and profile etc., can be provided in the AI-enabled model to forecast the Output data on Safe Refractory Lifetime, cause and effect analysis of wear mechanisms and scheduling of planned maintenance.

AI systems work on IOT integrated sensors network, video analytics, digital twin etc. that collect real time data from the operating units and feed into the AI analytics system to identify patterns and make data-driven predictions that improve the reliability and efficiency of these units by using fault detection diagnostics to indicate potential problems or failures.

In the days to come, AI analytics driven refractory solutions to customers will catch up fast and significantly scale up in the Steel and Cement plants.

Looking ahead, what next-generation refractory innovations hold the most promise for enabling ultra-low-carbon production in India’s steel and cement industries?

Next-generation innovations in refractory focus on enhancing sustainability, improving performance, and reducing environmental impact.

One of the key areas of innovation is the development of advanced refractory coatings and nano-structured materials. These materials offer superior heat resistance and thermal insulation, which helps in minimizing heat loss and optimizing energy usage. Additionally, the integration of AI-driven predictive analytics is revolutionizing the refractory industry by optimizing refractory lifespan, reducing downtime, and ensuring consistent thermal performance in steel and cement plants. These advanced analytics leverage vast amounts of data collected from various operational processes to predict the wear and tear of refractory materials accurately.

Nanotechnology plays a crucial role in the development of next-generation refractory materials. The incorporation of nanomaterials, such as nanoparticles and nano additives, has led to significant improvements in the mechanical, thermal, and chemical properties of refractories. These advancements not only extend the lifespan of refractory materials but also offer significant economic and environmental benefits, making them indispensable in modern industrial processes. Furthermore, innovations in kiln and refractory management, such as the adoption of AI-driven kiln control systems, are enhancing efficiency and reducing costs in cement manufacturing. These systems leverage machine learning to adjust kiln parameters in real-time, achieving higher stability and reducing fuel consumption.