Apparatus and methods for forming melt-formed fibres and melt-formed biosoluble fibers are disclosed. The apparatus comprises a spinning head comprising one or more rotors; a plurality of nozzles or slots disposed around at least part of the one or more rotors; a conveyor; and a barrier between the spinning head and the conveyor.

A nonwoven article comprising a two-dimensional nonwoven structure or a three-dimensional nonwoven structure comprising a plurality of discontinuous polycrystalline, aluminosilicate ceramic fibers that are cohesively bonded together by a fired precursor inorganic binder, wherein each cohesively bonded discontinuous fiber is bonded to one or a plurality of other said discontinuous fibers at one or more locations along its length.

A nonwoven article comprising a two-dimensional nonwoven structure having a longest major surface dimension and a shortest major surface dimension, said two-dimensional nonwoven structure comprising a plurality of discontinuous polycrystalline, aluminosilicate ceramic fibers having a length equal to the longest or shortest major surface dimension of the two-dimensional nonwoven structure or a length in between those dimensions.

Provided are a cover-layer-including ceramic continuous fiber suitable for producing a ceramic matrix composite material that can have improved damage tolerance and a ceramic matrix composite material formed from the cover-layer-including ceramic continuous fiber. The cover-layer-including ceramic continuous fiber includes a ceramic continuous fiber and a cover layer formed of an inorganic acid salt and disposed on the surface of the ceramic continuous fiber, wherein the thickness variation coefficient of the cover layer is 80% or less.

A hydrocracking catalyst for petroleum hydrocracking is provided, the hydrocracking catalyst provided in a form of at least one fiber, and the at least one fiber comprising at least one zeolite and at least one metal oxide. Methods are also provided to form the hydrocracking catalyst in the form of at least one fiber, particularly electrospinning.

A complex ceramic particle and ceramic composite material may be made of a pretreated coal dust and a polymer derived ceramic that is mixed together and pyrolyzed in a nonoxidizing atmosphere. Constituent portions of the particle mixture chemically react causing particles to increase in density and reduce in size during pyrolyzation, yielding a particle suitable for a plurality of uses including composite articles and proppants.

A needled blanket is provided comprising melt-formed inorganic fibres having an overall composition in weight percent SiO.sub.2: 47 to 65%; AI.sub.2O.sub.3: 35 to 53%; the blanket having a shot content, of shot >45 m, of less than 51 wt %, a specific surface area [BET)>0.25 m.sup.2.Math.g.sup.1. also disclosed are fibres for producing such blankets, and self-supporting products made from such fibres.

A hydrocracking catalyst for petroleum hydrocracking is provided, the hydrocracking catalyst provided in a form of at least one fiber, and the at least one fiber comprising at least one zeolite and at least one metal oxide. Methods are also provided to form the hydrocracking catalyst in the form of at least one fiber, particularly electrospinning.

A nonwoven web including a multiplicity of non-respirable, polycrystalline, aluminosilicate ceramic filaments entangled to form a cohesive mat, the polycrystalline, aluminosilicate ceramic filaments having an average mullite percent of at least 75 wt. %. The cohesive mat preferably exhibits a compression resilience after 1,000 cycles at 900 C. when measured according to the Fatigue Test, of at least 30 kPa. Insulation articles including the cohesive mats or formed by chopping the ceramic mats into ceramic fibers, pollution control devices including the insulation articles, and methods of making the non-respirable, polycrystalline, aluminosilicate ceramic filaments and fibers, nonwoven webs, insulation articles, and pollution control devices, are also described.

A complex composite particle is made of a coal dust and binder composite that is pyrolyzed. Constituent portions of the composite react together causing the particles to increase in density and reduce in size during pyrolyzation, yielding a particle suitable for use as a proppant or in a composite structure.