With short service life from tens of minutes to a few months due to the harsh conditions in Iron and Steel (I&S) making process, the refractory material consumption is substantial, leaving companies with significant challenges in the use, recycling, and disposal of these materials. In the current context of the European Green Deal, a Concerted European action on Sustainable Applications of REFractories (Doctoral Network CESAREF, www.cesaref.eu), has been launched in 2022 in order to develop better knowledge around refractory materials with regards to the new operating conditions requested by the drastic reduction of greenhouse gas emissions, improved energy efficiency, and by life cycle assessment requirements. The presented PhD study aims to predict refractory materials’ evolution in service, determine their reusability (to optimize material lifetime), and reduce operational costs. In order to achieve this goal, new sensoring systems will be created using non-destructive assessment techniques for online monitoring of important thermo-chemical and mechanical characteristics. This will generate data that machine learning algorithms may use to analyze the material's properties. The development of a precise numerical model that can evaluate the reusability and recyclability of refractory components is the overall goal of this novel technique. Such tools can, in the future, assist the end user in making a decision regarding the 4Rs (Reduce, Reuse, Recycle and Replace).