Skip to main content

Advertisement

SpringerLink
Log in

Preparation of porous mullite ceramic for high temperature flue gas filtration application by gel casting method

  • Research
  • Published:
Journal of the Australian Ceramic Society Aims and scope Submit manuscript

Abstract

In this study, porous mullite ceramics were prepared by gel-casting using fused mullite particles as the raw materials, ρ-Al2O3 and polysilicon waste as the binders, and starch as the pore forming agent. In addition, the effects of pore forming agent content on the apparent porosity, compressive strength, pore size distribution, thermal analysis, and pressure drop of porous mullite ceramics were studied. The results show that the as-prepared porous mullite ceramics have high apparent porosity, compressive strength, and gas permeability. Mullite phase formed in situ by adding polysilicon waste and ρ-Al2O3, which bonded the fused mullite particles and improved the performance of porous mullite ceramics. With increasing soluble starch content, the apparent porosity of the samples increased from 49.50 to 62.67%, and the compressive strength decreased from 4.98 MPa to 1.35 MPa. Furthermore, uniform pore size distribution and high gas permeability fully meet the requirements for the application of high-temperature flue gas filtration.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Subscribe and save

Springer+ Basic
$34.99 /Month
  • Get 10 units per month
  • Download Article/Chapter or eBook
  • 1 Unit = 1 Article or 1 Chapter
  • Cancel anytime
Subscribe now

Buy Now

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12

Similar content being viewed by others

Explore related subjects

Discover the latest articles, news and stories from top researchers in related subjects.

References

  1. Zhang, W.M., Guan, K., Liu, D.F., Cheng, P., Wu, J.Q.: Fabrication of super flux and high thermal shock resistance ceramic membrane support. Ceram. Int. 44, 21221–21228 (2018)

    Article  CAS  Google Scholar 

  2. Li, K., Thompson, S., Peng, J.X.: Modelling and prediction of NOx emission in a coal-fired power generation plant. Control. Eng. Pract. 12, 707–723 (2004)

    Article  Google Scholar 

  3. Zhao, Y., Wang, S.X., Duan, L., Lei, Y., Cao, P.F., Hao, J.M.: Primary air pollutant emissions of coal-fired power plants in China: current status and future prediction. Atmos. Environ. 42, 8442–8452 (2008)

    Article  CAS  Google Scholar 

  4. Yang, Y., Xu, W.Q., Zhang, F., Low, Z.X., Zhong, Z.X., Xing, W.H.: Preparation of highly stable porous SiC membrane supports with enhanced air purification performance by recycling NaA zeolite residue. J. Membr. Sci. 541, 500–509 (2017)

    Article  CAS  Google Scholar 

  5. Sand, M.M.S., Rashad, M.M., Abdel-Aal, E.A., El-Shaha, M.F.: Mechanical, morphological and dielectric properties of sintered mullite ceramics at two different heating rates prepared from alkaline monophasic salts. Ceram. Int. 39, 1547–1554 (2013)

    Article  Google Scholar 

  6. Osendi, M.I., Baudin, C.: Mechanical properties of mullite materials. J. Eur. Ceram. Soc. 16, 217–224 (1996)

    Article  CAS  Google Scholar 

  7. Schneider, H., Schreuer, J., Hildmann, B.: Structure and properties of mullite—a review. J. Eur. Ceram. Soc. 28, 329–344 (2008)

    Article  CAS  Google Scholar 

  8. Zake-Tiluga, L., Svinka, R., Svinka, V.: Highly porous corundum-mullite ceramics—Structure and properties. Ceram. Int. 40, 3071–3077 (2014)

    Article  CAS  Google Scholar 

  9. Yan, G.H., Liu, B.K., Yin, H.F., Li, J.X., Wang, W.X.: Effects of α-Al2O3 and SiO2 composite micropowders on properties of self-flowing andalusite castable. Refractories. 48, 208–210 (2014)

    CAS  Google Scholar 

  10. Hamidouche, M., Bouaouadja, N., Olagnon, C., Fantozzi, G.: Thermal shock behaviour of mullite ceramic. Ceram. Int. 29, 599–609 (2003)

    Article  CAS  Google Scholar 

  11. Medvedovski, E.: Alumina-mullite ceramics for structural applications. Ceram. Int. 32, 369–375 (2006)

    Article  CAS  Google Scholar 

  12. Ding, S.Q., Zeng, Y.P., Jiang, D.L.: Fabrication of mullite ceramics with ultrahigh porosity by gel freeze drying. J. Am. Ceram. Soc. 90, 2276–2279 (2007)

    Article  CAS  Google Scholar 

  13. Cuo, Z.X., Liu, H.D., Zhao, F., Li, W.M., Peng, S.P., Chen, Y.F.: Highly porous fibrous mullite ceramic membrane with interconnected pores for high performance dust removal. Ceram. Int. 44, 11778–11782 (2018)

    Article  CAS  Google Scholar 

  14. Luo, Z.Y., Han, W., Liu, K.Q., Ao, W.Q., Gu, J.: Hot mechanical properties of in-situ mullite-bonded silicon carbide supports. Refractories. 54, 201–204 (2020)

    Google Scholar 

  15. Bai, J.H.: Fabrication and properties of porous mullite ceramics from calcined carbonaceous kaolin and ɑ-Al2O3. Ceram. Int. 2010(36), 673–678 (2010)

    Article  Google Scholar 

  16. Cuo, Z.X., Zhang, J.Y., Yu, B., Peng, S.P., Liu, H.D., Chen, Y.F.: Spherical Al2O3-coated mullite fibrous ceramic membrane and its applications to high-efficiency gas filtration. Sep. Purif. Technol. 215, 368–377 (2019)

    Article  CAS  Google Scholar 

  17. Ebrahimpour, O., Dubois, C., Chaouki, J.: Fabrication of mullite-bonded porous SiC ceramics via a sol-gel assisted in situ reaction bonding. J. Eur. Ceram. Soc. 34, 237–247 (2014)

    Article  CAS  Google Scholar 

  18. Yang, F.K., Li, G.W., Lin, Y.M., Wang, C.A.: Effects of sintering temperature on properties of porous mullite/corundum ceramics. Mater. Lett. 73, 36–39 (2012)

    Article  CAS  Google Scholar 

  19. Lin, Y.C., Wang, T.Y., Lan, C.W., Tai, C.Y.: Recovery of silicon powder from kerf loss slurry by centrifugation. Powder Technol. 200, 216–223 (2010)

    Article  CAS  Google Scholar 

  20. Chen, W., Yao, C.J., Yin, Z.L., Liu, X.H.: Research on hydration properties of ρ-alumina (in Chinese). Naihuo Cailiao. 42, 271–273 (2008)

    CAS  Google Scholar 

  21. Yuan, L., Liu, Z.L., Hou, X.H., Tian, C., Zhu, Q., Wang, S.G., Ma, B.Y., Yu, J.K.: A novel aqueous gel-casting for fabricating Al2O3-bonded fifibrous mullite ceramics. J. Alloys Compd. 811, 152009 (2019)

    Article  CAS  Google Scholar 

  22. Hou, X.H., Liu, Z.L., Liu, Z.Q., Yuan, L., Yu, J.K.: Porous fifibrous ZrO2-mullite ceramics prepared via tert-butyl alcohol-based gel-casting. Ceram. Int. 44, 13580–13587 (2018)

    Article  CAS  Google Scholar 

  23. Hou, Z.G., Du, H.Y., Liu, J.C., Hao, R.H., Dong, X., Liu, M.X.: Fabrication and properties of mullite fiber matrix porous ceramics by a TBA-based gel-casting process. J. Eur. Ceram. Soc. 33, 717–725 (2013)

    Article  CAS  Google Scholar 

  24. Xu, L.C., Wang, E.H., Hou, X.M., Chen, J.H., He, Z.J., Liang, T.X.: Effect of incorporation of nitrogen on calcium hexaaluminate. J. Eur. Ceram. Soc. 40, 6155–6161 (2020)

    Article  CAS  Google Scholar 

  25. Bi, Y.B., Zhang, H.J., Wang, H.F., Jia, Q.L., Zhang, S.W.: Facile preparation of reduced GO modified porous ceramics with hierarchical pore structure as a highly efficient and durable sorbent material. J. Eur. Ceram. Soc. 40, 2106–2112 (2020)

    Article  CAS  Google Scholar 

  26. Han, L., Huang, L., Dong, L.H., Zhang, H.J., Pei, Y., Li, F.L., Jia, Q.L., Zhang, S.W.: Low temperature preparation of high-performance porous ceramics composed of anorthite platelets. J. Am. Ceram. Soc. 103, 5365–5373 (2020)

    Article  CAS  Google Scholar 

  27. Ding, D.F., Ye, G.T., Chen, L.G.: Superior corrosion resistance KAlSi2O6-containing materials for calcining Li-ion battery cathode materials. Corros. Sci. 157, 324–330 (2019)

    Article  CAS  Google Scholar 

  28. Wang, Q.H., He, G., Deng, S.X., Liu, J., Li, J.T., Li, Y.W., Pan, L.P., Liu, G.H., Li, X.Y., Li, J.Q.: Wettability and infiltration of Si drop on silica substrate containing α-Si3N4 coating: influence of oxygen content in α-Si3N4 coating. Ceram. Int. 46, 12695–12704 (2020)

    Article  CAS  Google Scholar 

  29. Deng, X.G., Wang, J.K., Liu, J.H., Zhang, H.J., Li, F.L., Duan, H.J., Lu, L.L., Huang, Z., Zhao, W.G., Zhang, S.W.: Preparation and characterization of porous mullite ceramics via foam-gel casting. Ceram. Int. 41, 9009–9017 (2015)

    Article  CAS  Google Scholar 

  30. Deng, X., Ran, S., Han, L., Zhang, H.J., Ge, S.T., Zhang, S.W.: Foam-gel casting preparation of high-strength self-reinforced porous mullite ceramics. J. Eur. Ceram. Soc. 37, 4059–4066 (2017)

    Article  CAS  Google Scholar 

Download references

Acknowledgements

The authors would like to express their gratitude for the financial support from the National Natural Science Foundation of China (Grant Nos. 51974074, 51874083), the State Key Program of National Natural Science Foundation of China (Grant No. 51932008), and the Fundamental Research Funds for the Central Universities (Grants N2025036, N182504009).

Author information

Authors and Affiliations

  1. School of Metallurgy, Northeastern University, Shenyang, 110819, People’s Republic of China

    Xinhua Yan, Lei Yuan, Zhenli Liu, Endong Jin, Chen Tian & Jingkun Yu

  2. State Key Laboratory of Rolling and Automation, Northeastern University, Shenyang, 110819, People’s Republic of China

    Jingkun Yu

Authors
  1. Xinhua Yan
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Lei Yuan
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Zhenli Liu
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Endong Jin
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Chen Tian
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Jingkun Yu
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Lei Yuan.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Yan, X., Yuan, L., Liu, Z. et al. Preparation of porous mullite ceramic for high temperature flue gas filtration application by gel casting method. J Aust Ceram Soc 57, 1189–1198 (2021). https://doi.org/10.1007/s41779-021-00613-1

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s41779-021-00613-1

Keywords

Search

Navigation