Silicic ester modified phenol/formaldehyde novolaks and their use for the production of resin coated substrates

Method of making a resin prepared by an acid-catalyzed reaction of a phenol/formaldehyde novolak with tetraethyl orthosilicate in a mass ratio range from 1000:1 to 28:1, wherein the phenol of the phenol/formaldehyde novolak is substituted or unsubstituted hydroxybenzene or a mixture of two or more such phenols, wherein the phenol/formaldehyde novolak has a molar ratio of phenol to formaldehyde in the range of from 1:0.5 to 1:0.95, the method comprising:

• preparing or providing a phenol/formaldehyde novolak, wherein the phenol of the phenol/formaldehyde novolak is substituted or unsubstituted hydroxybenzene or a mixture of two or more such phenols,
• reacting the phenol/formaldehyde novolak with tetraethyl orthosilicate in a mass ratio above 28:1,
• optionally distilling the product of the reaction of the phenol/formaldehyde novolak with tetraethyl orthosilicate to at least partially remove the ethanol formed during said reaction.

Method of making a resin-coated particulate material or mixture of particulate material with a resin, the method comprising:

• providing or making a resin prepared by an acid-catalyzed reaction of a phenol/formaldehyde novolak with tetraethyl orthosilicate in a mass ratio range from 1000:1 to 28:1, wherein the phenol of the phenol/formaldehyde novolak is substituted or unsubstituted hydroxybenzene or a mixture of two or more such phenols, wherein the phenol/formaldehyde novolak has a molar ratio of phenol to formaldehyde in the range of from 1:0.5 to 1:0.95,
• providing inorganic particles, and
• coating said inorganic particles with said resin.

Process of coating and/or binding a particulate material, wherein said particulate material is coated and/or bonded with a resin prepared by an acid-catalyzed reaction of a phenol/formaldehyde novolak with tetraethyl orthosilicate in a mass ratio from 1000:1 to 28:1, wherein the phenol of the phenol/formaldehyde novolak is substituted or unsubstituted hydroxybenzene or a mixture of two or more such phenols, wherein the phenol/formaldehyde novolak has a molar ratio of phenol to formaldehyde in the range of from 1:0.5 to 1:0.95.

Shell molding process for the production of a shell mold or a shell core, comprising:

• preparing or providing a resin-coated particulate material or mixture of particulate material with a resin, the particulate material or mixture comprising inorganic particles coated by or mixed with, respectively, a resin prepared by an acid-catalyzed reaction of a phenol/formaldehyde novolak with tetraethyl orthosilicate in a mass ratio range from 1000:1 to 28:1, wherein the phenol of the phenol/formaldehyde novolak is substituted or unsubstituted hydroxybenzene or a mixture of two or more such phenols, wherein the phenol/formaldehyde novolak has a molar ratio of phenol to formaldehyde in the range of from 1:0.5 to 1:0.95;
• producing a shell mold or a shell core comprising said resin-coated particulate material.

Hydraulic fracturing process, comprising:

• forming a fracture in a reservoir rock formation
• injecting a fluid into the fracture
• introducing a proppant into the injected fluid, said proppant comprising a resin-coated particulate material or mixture of particulate material with a resin, the particulate material or mixture comprising inorganic particles coated by or mixed with, respectively, the resin prepared by an acid-catalyzed reaction of a phenol/formaldehyde novolak with tetraethyl orthosilicate in a mass ratio range from 1000:1 to 28:1, wherein the phenol of the phenol/formaldehyde novolak is substituted or unsubstituted hydroxybenzene or a mixture of two or more such phenols, wherein the phenol/formaldehyde novolak has a molar ratio of phenol to formaldehyde in the range of from 1:0.5 to 1:0.95.

Process of making a resin bonded abrasive grinding, snagging or cut-off wheel, comprising:

• preparing or providing a resin-coated particulate material or mixture of particulate material with a resin, the particulate material or mixture comprising inorganic particles coated by or mixed with, respectively, the resin prepared by an acid-catalyzed reaction of a phenol/formaldehyde novolak with tetraethyl orthosilicate in a mass ratio range from 1000:1 to 28:1, wherein the phenol of the phenol/formaldehyde novolak is substituted or unsubstituted hydroxybenzene or a mixture of two or more such phenols, wherein the phenol/formaldehyde novolak has a molar ratio of phenol to formaldehyde in the range of from 1:0.5 to 1:0.95, wherein the inorganic particles comprise abrasive grains
• pressing the material to form a wheel
• curing the resin.