The present invention is a granular material that can be well recoated regardless of the type of the granular material, and enables a refractory aggregate in an unprinted portion to be used without any regeneration process, in the manufacture of a three-dimensional laminated and shaped mold. This granular material is a granular material for use in three-dimensional laminated mold shaping, and obtained by adding a material that causes a hydration reaction having a moisture absorbing function and generates a catalytic effect to a coating material mixed with or coated with an acid as a catalyst which activates and hardens an organic binder for binding the granular material.

A catalytic refractory heating appliance includes a body formed from a silicon carbide refractory material having a porosity that permits ionic oxygen to pass through the refractory material. The body defines a gas flow channel. A catalyst coating is on a surface of the refractory material of the body, whereby the refractory material becomes an active component with catalytic capability. For example, when the catalytic refractory heating appliance is a fire tube carbon dioxide and sulfur compounds can be directly absorbed, or carbon monoxide is reduced to methane.

Provided herein is a system, apparatus, and method for producing refractory products, and more particularly, to producing heated refractories, passive refractories, transition plates, moldable refractories, and accessories such as heated spouts, heated pins, thimbles, and dams. A heated refractory channel as disclosed herein may include a working surface to contain molten metal within the channel; a core adjacent to the working surface; one or more heating elements disposed within the core; and insulation, where the core is disposed between the working surface and the insulation. The one or more heating elements may be molded into the core. The heating elements may be electrical resistance heating elements.

Disclosed herein are fire resistant compositions and articles, for example, in the form of boards, insulation, sheeting, blocks, panels and similar materials of construction. Also disclosed are methods of preparing fire resistant compositions and articles and methods of use thereof.

The method is for use with a substrate having a plurality of parallel channels extending therethrough. In the method, the steps comprise: filling a selected plurality of the channels with a granular material; and consolidating the granular material through heat. The selected plurality of channels is selected to produce a wall that separates the substrate into: a first portion having a first plurality of the parallel channels extending therethrough; and a second portion having a second plurality of the parallel channels extending therethrough.

A castable refractory material for use in the manufacture of refractory products including fused silica, ceramic fiber, microsilica and a bonding material comprising colloidal silica.

Hydrophobic aggregates for use in refractory castables and gunning mixtures and methods of their preparation. The aggregates here are formed by crushing insulating fire brick and coating the resulting particles with a hydrophobic component. The hydrophobic component may be a polydimethylsiloxane having a terminal silanol group. As a result of the coating process, the coated aggregate has very low levels of alkalis. The aggregates may be used to form refractory castables that do not undergo substantial alkaline hydrolysis due to the reduced levels of alkalis. The castables made from these aggregates display superior physical properties, including lower water content, lower permanent linear change, high strength, and superior thermal conductivity/insulation properties, while at the same time possessing lower density and requiring less water to be used during castable formation. These improved properties also are observed in gunning mixtures formed from these aggregates.

A high temperature lightweight thermal insulating material is formed from a mixture that includes cement or silica sand, water and a foaming agent. The foaming agent can be an aluminum powder or a surfactant. The insulating material has a maximum use temperature greater than about 600 degrees Celsius.

An article may include a substrate, such as a silicon-containing ceramic matrix composite, an environmental barrier coating (EBC) layer on the substrate, and a CMAS-resistant EBC layer on the EBC layer. The EBC layer may include at least one rare-earth disilicate (REDS). The CMAS-resistant EBC layer may include at least one rare-earth monosilicate (REMS) configured to react with CMAS to form crystalline reaction products. The CMAS-resistant EBC layer may include a plurality of vertical cracks extending from a surface of the CMAS-resistant EBC layer at least partially into the CMAS-resistant EBC layer. Additionally, or alternatively, the EBC layer may include a plurality of vertical cracks extending from a surface of the EBC layer into at least a portion of the EBC layer.

A castable refractory composition comprises: a cement-free refractory particulate composition; and a sol binder; wherein the castable refractory composition comprises a metaphosphate-providing component and/or an orthophosphate-providing component.