Ahmed M.E. Khalil, Mohamed Egiza, Mohamed Ragab Diab, Elhashemi M. Ali, Dengrunyu Xie, Shaowei Zhang
High-temperature ceramics, particularly refractories, are essential components of energy-intensive industries, where they serve as linings for furnaces and reactors operating under extreme thermal and chemical conditions. However, conventional refractory production relies heavily on virgin raw materials and energy-intensive processing, while industrial waste streams are predominantly disposed of through landfilling or low-value applications, leading to resource inefficiency and environmental burden. This review addresses the critical challenge of integrating industrial by-products into high-performance ceramic systems by systematically analyzing the development of recycled waste-derived refractories (RWDRs). Emphasis is placed on waste selection, achievable waste loading, processing strategies, phase evolution, and thermo-mechanical performance. A wide range of industrial wastes, including red mud (∼44–45% Al₂O₃), fly ash (SiO₂-rich), blast furnace slag, spent refractories (>80% Al₂O₃), glass cullet, broken ceramics, and wastewater sludge, demonstrate strong compatibility with refractory formulations. Waste contents of up to 70 wt.% are reported without compromising key properties such as thermal shock resistance, bulk density, porosity, and mechanical strength. Furthermore, thermodynamic modelling enables phase control, while machine learning approaches support predictive optimization. Life cycle assessments confirm that RWDRs substantially reduce environmental impacts, particularly in terms of ecotoxicity and resource depletion, highlighting their technological feasibility and strategic importance for sustainable refractory manufacturing.