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1. (WO2001008833) SYSTEME DE DURCISSEMENT A BASSE TEMPERATURE
Note: Texte fondé sur des processus automatiques de reconnaissance optique de caractères. Seule la version PDF a une valeur juridique

CLAIMS

1. A binder composition for mixing with an aggregate and subsequently producing shape products, comprising a novolak resin and/or a resole resin and an accelerator.

2. Binder composition as claimed in Claim 1 wherein the novolak and/or resole resin comprises a phenolic novolak resin and/or a phenolic resole resin.

3. Binder composition as claimed in Claims 1 or 2 which comprises an additional solvent, and optional further additives.

4. Binder composition as claimed in any of Claims 1 to 3 wherein the composition is for mixing with a refractory aggregate for producing refractory shapes.

5. Binder composition as claimed in any of Claims 1 to 4 which comprises by % weight composition

Al - Novolak resin 25 - 80 %
A2 - The Resole resin 25 - 80%
A3 - The accelerator 5 - 20 % and
A4 - Additives 0 - 20% by weight

6. Binder composition as claimed in any of Claims 1 to 4 which comprises by % weight :

Al - Novolak resin 30 - 50% A2 - The Resole resin 40 - 70%
A3 - The accelerator 8 - 15% and
A4 - Additives 0 - 20% by weight

7. Binder composition as claimed in any of Claims 1 to 6 wherein the novolak resin is solid having molecular weight in the range 500 to 12,000.

8. Binder composition as claimed in any of Claims 1 to 7 wherein the resole is liquid.

9. Binder composition as claimed in any of Claims 1 to 8 wherein the accelerator is an activated phenolic species added in monomeric or oligomeric state.

10. Binder composition as claimed in any of Claims 1 to 9 wherein the accelerator is solid.

1 1. Binder composition as claimed in any of Claims 1 to 10 wherein the accelerator is added to the novolak in preference, over the resole.

12. Binder composition as claimed in any of Claims 1 to 1 1 wherein the accelerator is selected from monohydroxy or polyhydroxy species, preferably selected from phenol 1 ,3-dihydroxy-benzene

(resorcinol).

13. Binder composition as claimed in any of Claims 1 to 12 in the form of a two part binder system for mixing in situ comprising in a first part a novolak or resole resin and in the second part the accelerator.

14. Binder composition as claimed in Claim 13 which comprises in the first part a resole resin and in the second part a novolak resin and the accelerator.

15. A curable aggregate composition comprising a binder composition as hereinbefore defined in admixture with an aggregate.

16. Aggregate composition as claimed in Claim 15 wherein the aggregate is a refractory aggregate.

17. Aggregate composition as claimed in Claims 15 or 16 wherein the binder is included at a level of between 2 and 10% by weight, preferably between 3 and 6% by weight, the aggregate forms the balance of the mixture.

18. Binder or aggregate composition as claimed in any of Claims 1 to 17 wherein aggregates include quartz, silica, magnesia, alumina, zirconia, or chrome ore, e.g., chromite sand, and mixtures thereof.

19. Aggregate composition as claimed in any of Claims 15 to 19 in the form of a three part refractory aggregate system comprising a two part binder system as hereinbefore defined and in a third part a refractory aggregate.

20. Method of manufacturing cured aggregate shapes, comprising admixing a binder composition and aggregate as claimed in any of Claims 1 to 19 and curing at a temperature in the region of 100 - 200C, preferably 100 - 150C, for example 140C.

21. Method as claimed in Claim 20 wherein the binder components and aggregate are mixed and then shaped into bricks, placed on heat resistent pallets and cured whereby they are able to retain their shape, then coked, or assembled for use in refractory applications at elevated temperatures whereby they are subsequently coked in service.

22. Method as claimed in Claim 20 or 21 wherein curing is at a temperature in the region of 100-150C, on wooden heat resistant pallets.

23. An aggregate shape obtained with use of the composition and method as claimed in any of Claims 1 to 22.

24. The use of an aggregate shape as claimed in Claim 23 for heat or flame resistent insulation.

25. Use as claimed in Claim 24 of refractory bricks for the manufacture of a refractory mould to line ladles and the like for transferring molten steel in production, and for any other structures required to move molten metals.