Process for the Production of Carbon-Bonded Refractory Shaped Bodies or Masses with Improved Thermomechanical Properties

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This invention describes a method to manufacture carbon-bonded refractory bodies or masses with improved thermal and mechanical properties. The process uses a combination of traditional refractory materials, synthetic resin or similar binders, antioxidants, and a small amount of multiple nanoscale powders. The incorporation of nanoscale powders (with dimensions less than 50 nanometers) is central to achieving enhanced properties in the final product.

Use CasesContent extracted from patent full text and abstract with AI.

• Lining furnaces and kilns in steel and metal industries to withstand high temperatures and harsh chemical environments.
• Manufacturing crucibles, ladles, or other containers for molten metals.
• Producing high-performance refractory bricks for industrial applications.
• Applying in chemical reactors or incinerators that require durable heat-resistant materials.
• Improving components exposed to rapid heating and cooling cycles, reducing wear and extending their lifespan.

BenefitsContent extracted from patent full text and abstract with AI.

• Significantly improved thermo-mechanical properties, such as higher thermal shock resistance and mechanical strength.
• Increased lifespan and durability of refractory products, leading to reduced maintenance and downtime.
• Enhanced resistance to oxidation and chemical attack due to the inclusion of antioxidants and nanoscale powders.
• Ability to use less material (due to improved properties), potentially lowering costs and environmental impact.
• Compatibility with existing manufacturing processes for refractories, facilitating easy adoption in industry.

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Patent Abstract

Carbon-bonded refractory molded bodies or masses, comprises a mixture of an oxide, a non-oxide and/or carbon-containing refractory grains, a binder phase obtained from carbonization of a liquid binder, based on synthetic resin, bitumen, synthetic pitch and/or pitch, at least one antioxidant, and a combination of at least two nanoscale powders, which exhibit an average diameter of less than 50 nm, an average grain size of less than 50 nm, or an average platelet thickness of less than 50 nm, in an amount of less than 1wt.%, based on the molded body and the mass. An independent claim is also included for producing the carbon bonded refractory molded bodies or masses, comprising mixing the oxide, non-oxide and/or carbon-containing refractory grains with the liquid binder and at least one anti-oxidant in a feed mixture, and mixing the feed mixture with the combination of at least two nanoscale powders, and carbonizing the binder at greater than 800[deg] C.