Abstract: A bipolar plate for a fuel cell includes a conductive material, a novolac type phenol resin or a phenol dicyclopentadiene resin, and a compound having at least two ethylenically unsaturated double bonds. The conductive material is dispersed in an addition cross-linking reaction cured composition formed by the reaction of the novolac type phenol resin or the phenol dicyclopentadiene resin with the compound having at least two ethylenically unsaturated double bonds. Also, a method for manufacturing a bipolar plate for a fuel cell is provided, including the steps of mixing a conductive material, a novolac type phenol resin or a phenol dicyclopentadiene resin, and a compound having at least two ethylenically unsaturated double bonds, and heating and forming a resulting mixture into the shape of a bipolar plate.

Abstract: A process for forming a silicon nitride-bonded silicon carbide honeycomb monolith by a) forming a plasticizable mixture which includes (1) about 60% to 85% by weight, powdered silicon carbide with a median particle size of about 10-40 micrometers; (2) about 15% to 40% by weight, powdered silicon metal with a median particle size of about 5-20 micrometers; and, (3) organic components; b) extruding the plasticizable mixture to form a green honeycomb monolith; c) drying the green honeycomb monolith; and, d) heating the honeycomb monolith to 1450° C. with a hold of 1 hour in an atmosphere of argon; and, e) nitriding the honeycomb monolith between 1450° C. to 1600° C. for a time sufficient to obtain a silicon nitride-bonded silicon carbide body.

Abstract: While silicon-containing ceramics or ceramic composites are prone to material loss in combustion gas environments, this invention introduces a method to prevent or greatly reduce the thickness loss by injecting directly an effective amount, generally in the part per million level, of silicon or silicon-containing compounds into the combustion gases.

Abstract: A slag conditioner for extending the life of a BOF vessel lining utilizing recycled blast furnace filter cake dewatered by contact with a hot slag; its process of production, and method of use.

Abstract: A method of installing a refractory lining in a coreless or channel electric induction furnace. For installation of a refractory lining in a furnace wall, the method comprises the steps of providing a dry refractory material between a liner form placed within the furnace and a furnace wall, placing at least one variable frequency/amplitude electric vibrator in operational communication with an element selected from a structural member of the furnace, the liner form, and a vibrator rig placed within the furnace, inducing flow of the dry refractory material by operating at least one variable frequency/amplitude vibrator in a first operational mode having a high amplitude, low frequency vibration, and compacting the dry refractory material by operating at least one variable frequency/amplitude vibrator in a second operational mode having low amplitude, high frequency vibration after inducing flow of the dry refractory material.

Abstract: A mixture as described herein and a process for forming a coherent refractory mass on a surface of a refractory comprised of at least one silicon compound, the process including providing a mixture comprised of combustible particles including silicon particles, refractory particles of one or a plurality of substances which constitute a major portion by weight of the mixture, and particles of another substance or precursor thereof which are nonmetallic and which cause the incorporation of silica, formed by the combustion of silicon, into a crystalline lattice within the coherent refractory mass; and projecting the mixture against the surface of a refractory, simultaneously with oxygen, so that the combustible particles react in an exothermic manner with the projected oxygen and release sufficient heat to form the refractory mass under the action of heat of combustion.

Abstract: A dry refractory composition having superior insulating value. The dry refractory composition also may have excellent resistance to molten metals and slags. The composition includes filler lightweight material, which may be selected from perlite, vermiculite, expanded shale, expanded fireclay, expanded alumina silica hollow spheres, bubble alumina, sintered porous alumina, alumina spinel insulating aggregate, calcium alumina insulating aggregate, expanded mulllite, cordierite, and anorthite, and matrix material, which may be selected from calcined alumina, fused alumina, sintered magnesia, fused magnesia, silica fume, fused silica, silicon carbide, boron carbide, titanium diboride, zirconium boride, boron nitride, aluminum nitride, silicon nitride, Sialon, titanium oxide, barium sulfate, zircon, a sillimanite group mineral, pyrophyllite, fireclay, carbon, and calcium fluoride.

Abstract: Silica-based refractories are impregnated with protective material that is more resistant towards attack by corrosive species. The protective material coats the surface of the refractory matrix and fills some of the cavity volume of its pores, crevices, surfaces imperfections and irregularities. The protective material is positioned by impregnating the refractory with a precursor which, under the input of energy, is converted into the corrosion resistant protective material.

Abstract: An improved submerged entry nozzle is provided which is useful in the casting of aluminum killed molten steel. The nozzle has an improved slagline sleeve or collar which surrounds the outer portion of the nozzle to protect it from corrosion during the casting process. The slagline sleeve is made from resin bonded zirconia/graphite which has been formulated so that upon curing of the resin to form resite, there is a reduction in the contractile tendency which results in a reduction in stress fracturing. The reduction of the contractile tendency and the resulting resistance to stress fracturing is achieved by adding an effective amount of calcium oxide to the resin-zirconia-graphite mixture which is used to form the sleeve.

Abstract: A thermoplastic resin composition which comprises 100 parts by weight of thermoplastic resin as component (A) which is at least one species selected styrene resin, polycarbonate resin, and polyphenylene ether resin, and 0.5-100 parts by weigh of liquid crystalline polymer as component (B), said thermoplastic resin as component (A) having a glass transition point the rate of change of which satisfies the equation (1) below. Rate of change (%)=|(TgA−TgT)/TgA|×100≦5  (1) where TgA is the glass transition point of the thermoplastic resin as component (A), and TgT is the glass transition point attributable to the thermoplastic resin as component (A) in the resin composition.

Abstract: A method of relining a vessel that is used to carry out a direct smelting process that produces molten metal under conditions requiring molten bath temperatures of at least 1000° C. is disclosed. The vessel is of the type that has a floor that is refractory lined, a side wall that is at least partially refractory lined, and a top wall, and at least two access openings to the interior of the vessel. The relining method includes the steps of cooling down the vessel, gaining access to the interior of the vessel via the access openings, relining the vessel, and re-starting operation of the process in a period of time of 21 or less days.

Abstract: A method for forming a lining on the internal faces of a vessel involves installing a granular composition into a gap formed between the internal faces of the vessel and a mandrel. The granular composition is dropped into the gap in the form of a single mass.

Abstract: A method of applying a castable refractory composition using a form. The refractory composition consists essentially of from about 50.0 weight percent to about 99.9 weight percent of a high purity silicon dioxide and from about 0.1 weight percent to about 30.0 weight percent of a potassium silicate binder. About 0.1 weight percent to about 30 weight percent water based upon 100 weight percent of the refractory composition may be added to achieve a pumpable consistency of the refractory composition.

Abstract: A moving hearth is formed by providing a layer of hearth material primarily composed of iron oxide on a base refractory in a reducing furnace and then sintering the hearth material so that the sintered moving hearth is not melted at an operational temperature in a reducing step. The moving hearth is more easily constructed compared to providing a shaped or amorphous refractory on the base refractory, has high durability, and can maintain surface flatness during operation.

Abstract: The hot repair mix according to the present invention comprises bisphenol as an auxiliary fluidizing agent in an amount of 1 to 20 weight parts and a material to form carbon bond in hot working process in an amount of 5 to 40 weight parts to 100 weight parts of a refractory material. It has satisfactory properties such as spreading property, hardenability, adhesive property, property of the finished portion in hot working process, and this leads to improvement of durability of the baking material. Moreover, there is no change over time such as solidification, sedimentation separation, etc. in summer season, and it can be easily transported and stored. Because of easy handling and good workability of this material, baking operation can be accomplished within short time, and it is very useful as a hot repair mix for repairing various types of refinery furnaces, molten metal containers, etc. in hot working process.

Abstract: Silica-based refractories are impregnated with protective material that is more resistant towards attack by corrosive species. The protective material coats the surface of the refractory matrix and fills some of the cavity volume of its pores, crevices, surfaces imperfections and irregularities. The protective material is positioned by impregnating the refractory with a precursor which, under the input of energy, is converted into the corrosion resistant protective material.

Abstract: A repairing material for the bricks of the carbonizing chamber in a coke oven is obtained by compounding mortar as a main component with a powder comprising 70-100 wt. % of a Co compound, Ni compound, and/or Al compound and 0-30 wt. % of at least one compound selected from among the compounds of Ca, Mg, Zn, Sr, Ba, Fe, V, Pb, Cu, and Ti, and a liquid formed of water, B, P, and at least one member selected from among Si, Na, and K. A method for repairing includes hot applying the repairing material to portions of the bricks of the carbonizing chamber in the coke oven which are in need of repair.

Abstract: A spacing tool to be inserted between a form and a foundry furnace during installation of the form in the foundry furnace comprises a first longitudinally extending member to contact the foundry furnace. A second longitudinally extending member is coupled to the first member. The first and second members define opposed surfaces to contact the form and foundry furnace respectively. The second member is moveable relative to the first member to alter the distance between the opposed surfaces and set the spacing between the form and the foundry furnace. During a foundry furnace relining process, a plurality of spacing tools are used at circumferentially spaced locations to center the form within the foundry furnace.

Abstract: A monolithic refractory composition, which can be rapidly dried after being mixed with water and applied to a desired portion by casting or spraying to form a furnace wall, and which comprises refractory aggregates, a refractory powder, an aluminum alloy powder and a dispersant, wherein the aluminum alloy powder is contained in an amount of from 0.04 to 5 parts by weight per 100 parts by weight of the total amount of the refractory aggregates and the refractory powder.

Abstract: A device for supporting refractory material in a furnace environment is provided. In one embodiment, the supporting device is fabricated from individual pieces which are connected to produce a functional supporting device. The material supporting device provides an inverted channel-shaped base member structurally interengaged with a C-shaped member to provide support to material loads in an industrial setting. The C-shaped member has a pair of generally upwardly and inwardly projecting engagement flanges which provide interconnection with the base member. The base member has a pair of generally downwardly and inwardly projecting base flanges which provide support for refractory material. In another embodiment, interengagement between the C-shaped member and the base member may be further secured by conventional mechanical fastening apparatus and methods. A method of employing the above-described device and a method for using multiple supporting devices with one or more structural members are also disclosed.

Abstract: A method for placing a thixotropic low-cement castable refractory material without the necessity for forms. A low-cement castable material is mixed with a measured amount of water, then is pumped hydraulically through a hose to a nozzle assembly. Compressed air and a cement setting agent are added to the mixture at the nozzle. The addition of the setting agent at the nozzle overcomes the thixotropic nature of the low-cement castable, so that it will immediately "set" in position when sprayed onto a surface, including vertical and overhead surfaces.

Abstract: When the wall and bottom of a steel casting and handling ladle are provided at the same time with a refractory monolithic lining, the lining in the lower area of the wall is often damaged during intermediate repairs of the bottom. According to a new process, wall and bottom are lined one after the other. A hose-like inflatable sealing body is secured to the bottom part of the template 4 when beginning to introduce the casting mass in the wall area and is inflated so that it seals the template 4 up to the height that corresponds to the desired thickness of the bottom. As soon as the casting mass in the lower wall area is sufficiently set, the sealing body 2 is deflated and removed, then the refractory casting mass is introduced into the bottom area up to the desired height. This process is suitable for steel casting and handling ladles and for similar metallurgical vessels.

Abstract: A method of forming a sidewall for a reactor for oxidizing volatile or semi-volatile organic compounds, the sidewall being reactive with gaseous oxidation products produced by the oxidation of the volatile or semi-volatile organic compounds, includes, i) providing a dry mixture of material comprising by weight: from about 23% to 35% cement; from about 30% to 45% added CaO; from about 6% to 20% added Ca(OH).sub.2 ; and from about 10% to 25 % added CaSO.sub.4 ; ii) combining the dry mixture of material with water and forming a slurry therefrom; iii) forming the slurry into a desired reactor sidewall shape; and iv) hardening the shaped slurry into a hardened cement reactor sidewall.

Abstract: A process for applying a refractory castable onto a surface, comprising the steps of: (a) introducing metered amounts of a clay-free, dry refractory castable into a delivery hose, the dry refractory castable having an alumina content of about 40-95%; (b) conveying the dry refractory to a dispensing assembly under pneumatic pressure; (c) introducing water and a set modifying admixture into the dry refractory prior to dispensing the refractory castable from the dispensing assembly; and (d) spraying the hydraulic refractory castable onto a surface.

Abstract: It was difficult until now to carry out intermediate repairs of monolithic refractory lining walls of steel casting and handling ladles when the slag area of the lining was worn before other areas. According to this new process for reconstructing the refractory lining in the upper area of the wall, repairs may be economically carried out in that the gap between the lower end of the template and the lining that projects under the area to be reconstructed is sealed by inflating a hose-like sealing body and by deflating again the sealing body before removing the template. This process is useful for steel casting and handling ladles and for similar metallurgical vessels.

Abstract: A method is provided for installing a refractory lining in a blast furnace or other metallurgical vessel. A consumable form is installed along an inner surface of an outer shell of the metallurgical vessel. The consumable form is spaced apart from the outer shell. The metallurgical vessel is then filled with burden, which supports the consumable form. Casting composition may then be inserted between the consumable form and the outer shell. The casting composition is heated for a period of time before the burden is ignited. Cables which are lowered from the top of the vessel and secured at a lower end of the vessel may be used. Tubes mounted on panels may be threaded along the cables to position the panels in constructing the consumable form.

Abstract: A ceramic welding process for forming a coherent refractory mass on a surface of a refractory which is hot and which is comprised of at least one silicon compound includes providing a mixture composed of combustible particles including silicon particles, refractory particles which are silicon carbide particles and which constitute a major portion by weight of the mixture, and particles of one of (a) another substance selected from the group consisting of CaO, MgO, FeO, and mixtures thereof or (b) particles of a nonmetallic precursor of the another substance, which another substance causes incorporation of silica, formed by combustion of the silicon particles, into a crystalline lattice of a compound formed between the silica and the another substance within the coherent refractory mass being formed; and projecting the mixture against the surface of the refractory, simultaneously with substantially pure oxygen, so that the combustible particles react in an exothermic manner by combusting with the projected oxy

Abstract: A method for repairing industrial facilities at high temperatures using at least one prefabricated element made of a -mullite-crystallized refractory product with an alumina content of 30-85%, preferably 50-80%, made of refractory materials securely attached to the structure of the facility by using an oxygen containing carrier gas stream to spray a mixture of particles capable of exothermically reacting with the oxygen and particles of a refractory material, whereby a coherent refractory mass is formed in situ for attaching said element to said structure.

Abstract: A purging device for use in metal processing includes a shell, a body and a plurality of gas delivery tubes. The body comprises a refractory material and the tubes are disposed therein. Each tube has at least two passageways extending therethrough. The body with the tubes disposed therein is placed in the shell such that there is a gap between a portion of the body and the shell. An inlet allows the device to be attached to a lance, ladle or similar apparatus. Gas flows through the inlet, into the shell, through the passageways in the tubes and into the molten metal. In this manner, gas is delivered through the purging device through a plurality of passages that are arranged in discrete groups.

Abstract: A method for lining a blast furnace or other metallurgical vessel in stages uses a plurality of porous consumable forms and a pumpable casting composition. A form member, including a rigid support frame and a porous consumable form mounted thereto, is installed in a lower portion of the vessel being lined, and is spaced from the vessel wall. Casting composition is then pumped into the space between the consumable form and the vessel wall, and is permitted to harden. Then, another form member is positioned above the first, and casting composition is pumped into the space between the second form member and the vessel wall. This process is repeated, using stacked form members, until the refractory lining is completely installed.

Abstract: A method of repairing damaged hot refractory linings in high-temperature vessels includes forming an opening through the outer shell of the vessel proximate to the damaged region of the hot refractory lining, and introducing a refractory material into the damaged region. The refractory material is rapidly injected in a sufficient amount to effect complete filling, and is fast curing to strength at the operating temperature of the vessel. The method eliminates the need to allow the vessel to cool down to ambient temperature and then reheat the vessel to operating temperature thereby eliminating thermal cycling of the refractory lining.

Abstract: A circular, surface-coating application of sprayable composition or mortar is achieved through a rotatable spray head with at least one lateral discharge opening. The composition or mortar is distributed as uniformly and over as large a surface area as possible in the vicinity of the spray head. The spray head is moved axially forwards and back in an axial direction through the same distance during conveying of the composition or mortar and is rotated automatically through the same angular distance about the axis.

Abstract: When casting castable refractories as lining refractories of a ladle for a molten metal, wherein the castable refractories are prepared by kneading monolithic refractories with an aqueous solution of a binder containing alumina cement, the castable refractories are preheated on the basis of the open air temperature and cured after casting while keeping the temperature thereof within a set temperature range of from about 20.degree. C. to 40.degree. C. The method stabilizes the hardening time of castable refractories and forms cast refractories excellent in strength and erosion resistance.

Abstract: A process for producing a crystalline siliceous refractory mass includes providing particulate constituents to be projected comprised of (1) solid refractory particles comprising silica in the form of vitreous silica, and (2) solid combustible particles comprising silicon particles; projecting the particulate constituents with gaseous oxygen against a surface under ceramic welding conditions effective to cause a reaction between the solid combustible particles and the gaseous oxygen to occur against the surface, thereby releasing the heat of reaction against the surface so that a coherent refractory mass comprising cristobalite is formed, wherein the surface against which the solid refractory particles are projected is at a temperature of at least 1000.degree. C. The process can be used to manufacture refractory bricks or blocks, to repair furnaces, or to repair worn surfaces of a siliceous refractory material.

Abstract: A process for coating the walls of a steelmaking vessel with slag between heats to protect the refractory liming of the vessel uses coolant in the form of recycled slag as a substitute for fluxes such as lime and dolime to cool and thicken slags which are otherwise too fluid to produce an acceptable slag coat.

Abstract: A repairing method using a lance for repairing an oven wall surface of a coke oven comprises the steps of arranging a distance sensor at a top end of the lance, quantitatively measuring a depth of a worn or a damaged area by the distance sensor, and blowing a repairing material from a repairing nozzle to the worn area in accordance with a measurement result to thereby repair the worn area. The lance used in this repairing method has a multistage structure having a polygonal cross section and is extendable. With this structure, the oven wall surface can be scanned in a linear fashion or along a plane. If the top end of the lance is movable in accordance with a basic motion pattern and/or a travelling pattern, it is possible to readily repair a repair range having a complicated shape.

Abstract: A refractory brick that has a rear portion with a geometrical concavity on one side and a corresponding convex projection on the other side, the concavity and projection being matched so that the concavity mates with the corresponding projection of a similar refractory brick when the two are disposed in side-by-side relationship. Extending perpendicular from the base portion is a generally rectangular projection such that when a plurality of bricks are disposed in a side-by-side array, they are locked together by the mating concavities and projections, and the generally rectangular projections extend inwardly to form a thicker lining to withstand the force of a tap stream of molten metal for a longer duration.

Abstract: A method of repairing an oxide-based refractory body by projecting a powder mixture against a hot surface of the body and in the presence of oxygen to provide a refractory repair mass includes providing a powder mixture composed of particles of at least one refractory oxide; fuel particles which react in an exothermic manner with the oxygen to form a refractory oxide and which are particles composed of at least one element selected from the group consisting of magnesium, aluminum, silicon, and mixtures thereof; and particles of silicon carbide present in an amount which is effective to provide a reduced porosity of the refractory repair mass and which does not exceed 10% by weight based on the weight of the powder mixture; and projecting the powder mixture against a hot surface of the oxide-based refractory body and in the presence of oxygen. Preferably, the powder mixture contains at least 1%, most preferably from 1 to 5%, by weight of the particles of silicon carbide.

Abstract: A process for forming a coherent refractory mass on a surface of a refractory, which refractory includes at least one silicon compound, the process including providing a mixture including (1) combustible particles including silicon particles, (2) refractory particles of one or a plurality of substances which constitute a major portion by weight of the mixture, and (3) particles of another substance or precursor of the another substance which particles are nonmetallic and which another substance causes incorporation of silica, formed by combustion of the silicon particles, into a crystalline lattice of a compound formed between the silica and the another substance within the coherent refractory mass to be formed; and projecting the mixture against the surface of a refractory, simultaneously with oxygen, so that the combustible particles react in an exothermic manner with the projected oxygen and release sufficient heat to form the coherent refractory mass under action of heat of combustion and so that silica i

Abstract: The procedure for manufacturing fireproof crucibles for steel-processing ladles, in which aluminum deoxidation is carried out for the total quenching of liquid steel, is such that a monolithically hardening fireproof mass with a proportion of silicon dioxide is placed between the inside wall of the ladle and a reusable plug that is installed therein. After the plug has been removed, the ladle is put into use again, at which time a layer that contains alumina builds up on the hot side of the fireproof crucible and a highly sintered layer of greater hardness forms behind this. It is intended that a procedure such as this should simplify the reestablishment of the fireproof lining when the limits of use are reached, in view of the use of a layer that contains alumina and the highly sintered layer located behind this on the inside wall of the crucible.

Abstract: An electrolytic cell for the electrowinning of aluminium from alumina dissolved in a halide-containing molten electrolyte, has a cathode cell bottom made of a series of carbon cathode blocks (10) connected side-by-side by glue or ramming paste, each one provided with steel or other conductive bars (11) for the delivery of current and a series of anodes (15) facing the cathode cell bottom. The tops of the carbon blocks (10) forming the cathode cell bottom are shaped in such a way as to provide in the cell bottom a series of parallel channels (25) or grooves preferably coated with an aluminium-wettable refractory coating (35) covered in use by a pool (40) of molten aluminium or a layer of molten aluminium forming a drained surface. Movement of the aluminium pool (40) is decreased, cell operation improved and cell life extended.

Abstract: A process for repairing bottom linings of D.C. arc furnaces. A refractory ceramic mass is used for lining the bottoms of D.C. arc furnaces in the area of metallic electrodes placed therein, wherein the refractory ceramic mass comprises one or more refractory oxides, in a grain fraction of less than 8 mm and 10 to 40 wt. % of finely dispersed metallic additives in a grain fraction of less than 0.1 mm, for lining bottoms of D.C. furnaces in the area of metallic electrodes, placed within said bottoms to insure an electrically conductive contact between the refractory ceramic mass and the metallic electrodes.

Abstract: A method is provided for installing a refractory lining in a metallurgical vessel having a main opening which is much smaller than the diameter of the vessel. The method is especially useful in a vessel having a circular or otherwise curved cross-section. A form or mold is assembled inside the vessel, leaving a space between the form and the outer shell of the vessel. The form is supported on both sides, to maintain the distance between the form and the outer shell, and to prevent collapse or implosion of the form. Then, a pumpable casting composition having a smooth and easy flow is injected between the form and the shell, and allowed to harden. The use of the pumpable composition significantly shortens the time required to form the liner.

Abstract: A method for placing a thixotropic low-cement castable refractory material without the necessity for forms. A low-cement castable material is mixed with a measured amount of water, then is pumped hydraulically through a hose to a nozzle assembly. Compressed air and a cement setting agent are added to the mixture at the nozzle. The addition of the setting agent at the nozzle overcomes the thixotropic nature of the low-cement castable, so that it will immediately "set" in position when sprayed onto a surface, including vertical and overhead surfaces.

Abstract: A filter for use in a coupling disposed between first and second tubes which convey lime from a movable carrier to a processing pot in a steel mill. The filter has a plurality of openings sized and positioned to allow passage of lime and exclude contaminants of a size larger than the size of the perimeter of selected openings reduces erosion by the lime.

Abstract: A process for producing an inner refractory lining of a ladle or metallurgical vessel for casting steel. The inner refractory lining incorporates wall passages with conical nozzle bricks and/or bubble bricks. The inner lining is produced by using a thixotropic vibrational lining mass. Templates are employed to maintain openings for the wall passages during production of the inner lining. After the inner lining is produced, the templates are removed from the inner lining. Once the templates are removed from the inner lining, the conical nozzle bricks and/or the bubble bricks are inserted into the openings. Each of the bricks is mortared into an opening without using seating blocks. The bricks are mortared into the openings so that the bricks remain free from contact with the inner lining.

Abstract: A method of manufacturing an open top, walled member for containing a molten metal, including the steps of forming an inner wall of a mold with a metal sheet and an inner lining covering the sheet, wherein the inner wall defines an inside surface of the walled member and transferring a casting compound between an outer wall of the mold and the inner lining of the inner wall to form the walled member. The metal sheet and inner lining are then removed to allow one to apply heat to dry the casting compound. In the case where the metal sheet includes a plurality of openings, one may also retain the inner wall during the heating step. The heat to dry the casting compound is applied to the inner lining to a sufficient temperature to melt the inner lining and uncover said openings of the metal sheet. The metal sheet is removed when the casting compound is dried.

Abstract: A method of manufacturing an open top, walled member for containing a molten metal, especially a flowing molten metal or reconstructing a worn or damaged member. The method includes the step of forming the inner walls of a mold which define the inner surfaces of the walled member of an open metal mesh screen which is meltable by the molten metal which is to be contained. The next step is to transfer, usually by pumping, an alumina-silicon carbide casting compound into the space between the open mesh metal screen and the outer walls defining the mold, which outer walls may be in situ structures. If an existing walled member is being repaired, any damaged or worn portions of the existing walled member are removed and the casting compound is poured in to replace these portions. The next step is to apply heat to dry the casting compound while the open mesh screen of the mold remains in place in contact with the casting compound.

Abstract: A process for manufacturing a flue made of fiber-reinforced plastic (FRP), particularly of a stack for discharging chemically aggressive fumes, consists of manufacturing the FRP flue directly inside the stack. The apparatus for performing this process includes a rotating carousel which supports a first work station, a second work station and at least a third work station to progressively and constantly deposit on a stationary mold at least one first layer of chemically-resistant material and at least one layer of mechanically-resistant material in order to form, without discontinuities, a central portion of the flue of the stack.

Abstract: An improved castable refractory composition having excellent resistance to attack from slag can be efficiently transported to a destination, such as a mold, using a pump. The castable refractory composition includes about 36-92% by weight silicon carbide, about 8-20% by weight of a colloidal silica binder, and a balance substantially of other refractory materials which can include alumina, microsilica, graphite, and a setting agent. The composition of the invention can be used alone or in addition to a conventional refractory casting material to form a refractory lining. When used together, the conventional refractory composition is used to construct a lower layer in the refractory lining, and the composition of the invention is used to construct an upper refractory layer above the lower layer.