This project transforms recycled concrete fines (RCFs) from construction and demolition (C&D) waste to be used as supplementary cementitious materials (SCMs), thereby converting these fine concrete wastes into cement (CEMCON). The main objectives are to characterize and categorize RCFs from various recycling plants, develop a treatment method to activate different types of RCFs, and understand the performance and environmental impacts of these activated RCFs when used as SCMs.

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ECO2LIFE is developing new methods for the monitoring, modelling and predictive maintenance of BOF converters (Basic Oxygen Furnaces). The aim is to better understand the degradation mechanisms affecting the refractory lining and steel shell, detect critical damage early, and derive targeted maintenance measures. To this end, existing process and sensor data are combined with innovative measurement methods. The data is processed and used to validate detailed thermal and thermo-mechanical finite element models of the refractory lining and the steel shell.

Link to K1-MET Metallurgisches Kompetenzzentrum 

REFFRACTEUR develops new digital, sustainable and circular solutions for refractory materials, which are essential in energy-intensive high-temperature processes such as steel, cement, glass and non-ferrous-metal production. The project brings together materials science, process and mechanical engineering, digital technologies and sustainability assessment. Its objective is to improve the understanding, design, use and high-value recycling of refractory materials throughout their entire life cycle. To achieve this, REFFRACTEUR combines digital product passports, life-cycle assessment, sensor-based quality control, artificial intelligence and digital twins.

Through this integrated approach, the project aims to reduce raw-material and energy consumption, CO₂ emissions, waste volumes and costs. REFFRACTEUR therefore contributes to a resource-efficient, safe, competitive and resilient European process industry.

Link to REFFRACTEUR 

The demand for climate-friendly, recyclable, CO₂-reduced building materials is growing rapidly in view of the climate crisis, resource scarcity and stricter regulations (e.g. life cycle balances, circular economy). The construction sector is a major contributor to global emissions; the lever over materials with a low CO2 footprint, long service life and high recyclability is correspondingly large. Against this background, the Chair of Mineral Metallurgy is researching the optimisation of sustainable insulation materials based on mineral foam.

Mineral foam is a porous, mineral insulation material that is produced from resource-efficient components such as sand, lime and cement-bound systems through a drifting and foaming process. It is non-flammable, permeable to diffusion and capillary-active, which makes it particularly safe and robust in terms of building physics. Compared to many synthetic alternatives, an all-mineral matrix offers advantages in fire protection, ageing resistance and potential recyclability. In addition, the material proximity to mineral building products will enable better integration into cycles in the future – from the use of secondary raw materials to high-quality recycling at the end of life.

Our research focus is on low-CO₂ formulation development and optimization. We integrate CO₂-reduced binders and explore the influence of other additives without sacrificing thermal performance or compressive strength. The key levers are a deep understanding of the interaction of the raw materials, the control of foam stability and a stable, not too narrow process window for further processing.

In a project cooperation with Miralis GmbH, we are bundling scientific and industrial expertise in order to transfer the developed mineral foam systems to an industrial scale. Together, we work on the scale-up steps from recipe optimization to continuous foam generation and shaping to drying and quality assurance. In doing so, we are testing the use of secondary raw materials to further reduce the carbon footprint and evaluating alternative formulation components to ensure supplier independence.

The goal is a high-performance, industrially scalable and recyclable mineral foam with a significantly reduced CO₂ footprint – an insulation material that meets the technical requirements of modern building envelopes and at the same time accelerates the transformation towards a sustainable, resource-saving construction industry. The cooperation with Miralis GmbH enables rapid validation on a pilot and pre-series scale and creates the basis for a rapid market launch.

Contact: Christina Atzenhofer