Reaction-sintered porous mineral-based mullite ceramic membrane supports made from recycled materials |
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Authors: | Yingchao Dong Jian-er Zhou Bin Lin Yongqing Wang Songlin Wang Lifeng Miao Ying Lang Xingqin Liu Guangyao Meng |
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Affiliation: | a Key Lab of Jiangxi Universities for Inorganic Membranes, National Engineering Research Center for Domestic and Building Ceramics, Jingdezhen Ceramic University (JCU), Jingdezhen, Jiangxi, 333001, PR China;b USTC Lab for Solid State Chemistry and Inorganic Membranes, Department of Materials Science and Engineering, University of Science and Technology of China (USTC), Hefei, 230026, PR China |
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Abstract: | Bulk porous mullite supports for ceramic membranes were prepared directly using a mixture of industrial waste fly ash and bauxite by dry-pressing, followed by sintering between 1200 and 1550 °C. The effects of sintering temperature on the phase composition and shrinkage percent of porous mullite were studied. The XRD results indicate that secondary mullitization reaction took place above 1200 °C, and completed at 1450 °C. During sintering, the mixture samples first shrunk, then expanded abnormally between 1326 and 1477 °C, and finally shrunk again above 1477 °C. This unique volume self-expansion is ascribed to the secondary mullitization reaction between bauxite and fly ash. More especially, the micro-structural variations induced by this self-expansion sintering were verified by SEM, porosity, pore size distribution and nitrogen gas permeation flux. During self-expansion sintering, with increasing temperature, an abnormal increase in both open porosity and pore size is observed, which also results in the increase of nitrogen gas flux. The mineral-based mullite supports with increased open porosity were obtained. Furthermore, the sintered porous mullite membrane supports were characterized in terms of thermal expansion co-efficient and mechanical strength. |
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Keywords: | Membrane supports Mullite Self-expansion sintering Fly ash Waste recycling |
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