Sustainable silico-aluminous refractory wastes as an alternative raw material for hydraulic binder for foundry industry

[Display omitted] •Refractory wastes can be repurposed for creating new refractory hydraulic set mass.•The wastes were classified as non-inert and were not deemed hazardous.•The iron contamination did not exhibit significant changes in thermal behavior.•Particle size dispersion and reduction in the coarse fraction caused strength gain.•There is potential for cost savings of at least 25 % promoting a culture of recycling. The foundry industry is responsible for consuming large quantities of lining materials and generating significant amounts of waste. Silico-aluminous linings are used in the production of cast iron due to their compatibility with molten metal and slag. However, after use, these materials are typically disposed of in industrial landfills, creating an environmental liability. This study demonstrated a feasible alternative approach to repurpose silico-aluminous refractory wastes from induction furnaces and casting ladles from the foundry industry to develop new materials for refractory hydraulic binders for lining (refractory patch). The wastes were characterized using X-ray Diffraction, X-ray Fluorescence Spectrometry, Thermal Analysis, Scanning Electron Microscopy, and particle size distribution. The behavior of the lining wastes was found to be compatible with the proposed application, despite the expected contamination. There is potential for cost savings of at least 25 % and promoting a culture of recycling.