High temperature expandable refractory

1. An expandable refractory for high temperature sealing, the expandable refractory comprising:

un-expanded vermiculite; and

at least one mixture of ceramic fibers in a water based refractory binder;

the expandable refractory is configured for sealing by having a first volume prior to heating the expandable refractory and the expandable refractory having a second volume after the heating, the second volume being greater than the first volume.

2. The expandable refractory of claim 1 , wherein:

the un-expanded vermiculite is present at 5 vol. % to 25 vol. %; and

the mixture of ceramic fibers in the water based refractory binder is present at 75 vol. % to 95 vol. %.

3. The expandable refractory of claim 1 , wherein:

the un-expanded vermiculite is present at 5 vol. % to 6 vol. %; and

the mixture of ceramic fibers in the water based refractory binder is present at 94 vol. % to 95 vol. %.

4. The expandable refractory of claim 1 , wherein:

the un-expanded vermiculite is present at 24 vol. % to 26 vol. %; and

the mixture of ceramic fibers in the water based refractory binder is present at 73 vol. % to 76 vol. %.

5. The expandable refractory of claim 1 , wherein:

the un-expanded vermiculite is present at 19 vol. % to 21 vol. %; and

the mixture of ceramic fibers in the water based refractory binder is present at 79 vol. % to 81 vol. %.

6. The expandable refractory of claim 1 , wherein:

the un-expanded vermiculite is present at 12 vol. % to 13 vol. %; and

the mixture of ceramic fibers in the water based refractory binder is present at 87 vol. % to 88 vol. %.

7. The expandable refractory of claim 1 , wherein:

the un-expanded vermiculite is present at 4 wt. % to 6 wt. %; and

the mixture of ceramic fibers in the water based refractory binder is present at 94 wt. % to 96 wt. %.

8. The expandable refractory of claim 1 , wherein the at least one mixture of ceramic fibers in a water based refractory binder is pumpable.

9. The expandable refractory of claim 1 , wherein the at least one mixture of ceramic fibers in a water based refractory binder is moldable.

10. A method of curing an expandable refractory, the method comprising:

providing an expandable refractory comprising un-expanded vermiculite and at least one mixture of ceramic fibers in a water based refractory binder the un-expanded vermiculite is present at 5 vol. % to 25 vol. %; and the mixture of ceramic fibers in the water based refractory binder is present at 75 vol. % to 95 vol. %;

heating the expandable refractory to 1200° F.; and

wherein the expandable refractory is maintained at the 1200° F. for at least two hours.

11. A method of curing an expandable refractory, the method comprising:

providing an expandable refractory comprising un-expanded vermiculite and at least one mixture of ceramic fibers in a water based refractory binder the un-expanded vermiculite is present at 5 vol. % to 25 vol. %; and the mixture of ceramic fibers in the water based refractory binder is present at 75 vol. % to 95 vol. %;

heating the expandable refractory to 1200° F.; and

wherein the expandable refractory is held at a temperature of about 195° F. to about 220° F. for about one hour prior to the heating the expandable refractory to the 1200° F.

12. A method of curing an expandable refractory, the method comprising:

providing an expandable refractory comprising un-expanded vermiculite and at least one mixture of ceramic fibers in a water based refractory binder the un-expanded vermiculite is present at 5 vol. % to 25 vol. %; and the mixture of ceramic fibers in the water based refractory binder is present at 75 vol. % to 95 vol. %;

heating the expandable refractory to 1200° F.; and

wherein the expandable refractory is heated to the 1200° F. at a rate of about 0.5° F. per minute to about 20° F. per minute.

13. A method of curing an expandable refractory, the method comprising:

providing an expandable refractory comprising un-expanded vermiculite and at least one mixture of ceramic fibers in a water based refractory binder the un-expanded vermiculite is present at 5 vol. % to 25 vol. %; and the mixture of ceramic fibers in the water based refractory binder is present at 75 vol. % to 95 vol. %;

heating the expandable refractory to 1200° F.; and

wherein the expandable refractory is heated to the 1200° F. at a rate of about 15° F. per hour to about 30° F. per hour.

14. The expandable refractory of claim 1 , wherein the second volume is 5 to 50 percent greater than the first volume.

15. . The expandable refractory of claim 1 , wherein the second volume is 40 to 50 percent greater than the first volume.

16. The expandable refractory of claim 1 , wherein the second volume is 5 to 10 percent greater than the first volume.

17. The expandable refractory of claim 1 , wherein the heating comprises heating to 1200° F.

18. The expandable refractory of claim 1 , wherein expansion of the expandable refractory from the first volume to the second volume occurs one time when the heating is at a temperature of 212° F.

19. A fuel cell power plant comprising:

a fuel cell module comprising an enclosure having at least one fuel cell system disposed therein;

a gap defined between the at least one fuel cell system and the enclosure; and

an expandable refractory expanded in the gap by a one-time heating, the expandable refractory comprising:

un-expanded vermiculite; and

at least one mixture of ceramic fibers in a water based refractory binder; and

the expandable refractory having a first volume prior to the heating the expandable refractory and the expandable refractory having a second volume after the heating, the second volume being greater than the first volume and filling the gap.

20. The fuel cell power plant of claim 19 , wherein the expandable refractory is adhered to the enclosure and the fuel cell system.

21. The fuel cell power plant of claim 19 , wherein the expandable refractory comprises a seal that seals the gap.

22. The fuel cell power plant of claim 19 , further comprising a second refractory having at least one crevice formed therein, said crevice having the expandable refractory pumped therein, the expandable refractory being expanded in and sealing the crevice.

23. A fuel cell power plant comprising:

a fuel cell module comprising an enclosure having at least one fuel cell system disposed therein;

at least one penetration extending through the enclosure; and

an expandable refractory expanded in the at least one penetration by a one-time heating, the expandable refractory comprising:

un-expanded vermiculite; and

at least one mixture of ceramic fibers in a water based refractory binder; and

the expandable refractory having a first volume prior to the heating the expandable refractory and the expandable refractory having a second volume after the heating, the second volume being greater than the first volume and filling the at least one penetration.

24. The fuel cell power plant of claim 23 , wherein the expandable refractory is adhered to the enclosure and the at least one penetration.

25. The fuel cell power plant of claim 23 , wherein the expandable refractory comprises a seal that seals the penetration.

26. The fuel cell power plant of claim 23 , further comprising a second refractory having at least one crevice formed therein, said crevice having the expandable refractory pumped therein, the expandable refractory being expanded in and sealing the crevice.