R4 is the Key!

Deposits of premium quality raw materials are depleting at a faster rate due to over exploitation and measures must be taken to preserve them for future generations. Calderys India Refractories Limited makes all the efforts to develop environmentally friendly technologies to save minerals that are on the verge of extinction. In the context of refractories R4 project targets to reduce virgin raw material utilization by reusing the dismantled lining material, developing a process of making the dismantled material suitable for refractory formulations, i.e. repair and finally repeat the process, viz. Recycle. Prior to the development of the R4 concept, dismantled refractories were used for land filling or road construction. The project aims to develop techno-economic solutions by producing high-performance greener products using materials salvaged from dismantled refractory lining. The project work involves identification of the alternative raw materials and their right source, performing extensive testing, and product reformulation. It also includes responsible supply chain management and upskilling the sub-vendors to increase their technical know-how and ability to supply the right grades of raw materials. This process conserves precious resources, requires less mining, reduces quantities ending up in landfill, and uses less energy. Discarded used refractories are basically of two types, bricks and monolithics. Used monolithic lining often has metallic elements embedded in it, which makes it difficult to reprocess compared to bricks. At the same time, monolithic products offer immense potential for the use of recycled refractories. The recovered refractory materials originate from diverse industries such as iron and steel, glass, electrical insulators, aluminium, etc. and hence it is critical to analyze and evaluate them for the presence of any adverse constituents to decide the right usage. In this way, R4 aims to find a balance between sustainability and profitability. Our consistent efforts have given us a CAGR for recycled material consumption of 10.8% for the period of 2015–2020.