Thermosetting resins for carbon-containing refractories: Theoretical basis and novel insights

Thermosetting resins (TR) are organic compounds that form rigid solid polymers that under heating, decompose with no plastic state or melting. Such an aspect is useful for their application in refractory systems. Despite their technological importance, few works have systemically discussed how TR composition and molecular architecture, the curing conditions and the presence of additives influence the properties of carbon-containing refractories after pyrolysis, graphitization and sintering processes. The present paper review the benefits and drawbacks of applying TR to produce carbon-containing refractories. The first sections present general aspects of TR synthesis and chemical modification. The influence of the processing conditions, raw materials and additives on the pyrolysis of organic material, carbon yield generation and phase transformations are discussed. Additionally, important aspects about toxicity and safety issues of several types of TR, the use of different grades attained from sustainable raw materials, and future challenges for TR-bonded refractories’ production are pointed out. [Display omitted] •Thermosetting resins may replace coal-tar pitches as binders in refractory products.•Novolaks and resoles are the most common resins applied in refractories.•The 3D-structure derived from crosslinking is essential for enhancing carbon yield.•Catalytic graphitization is the most effective method to induce carbon crystallization.•Thermosetting resins can be produced from raw materials derived from renewable sources.