Mullite Membrane

In this study, high-performance FAU (NaY type) zeolite membranes were successfully synthesized using small-sized seeds of 50 nm, and their gas separation performance was systematically evaluated. Employing nano-sized NaY seeds and an ultra-dilute reaction solution with a molar composition of 80 Na2 O: 1Al2 O3 : 19 SiO2 : 5000H2 O, the effects of synthesis temperature, crystallization time, and porous support (α-Al2 O3 or mullite) on the formation of FAU membranes were investigated. The results illustrated that further extending the crystallization time or increasing the synthesis temperature led to the formation of a NaP impurity phase on the FAU membrane layer...

Membrane technology is a promising method for gas separation. Due to its low energy consumption, environmental safety, and ease of operation, membrane separation has a distinct advantage over the cryogenic distillation conventionally used to capture light inert gases. For efficient gas recovery and purification, membrane materials should be highly selective, highly permeable, thermally stable, and low-cost. Currently, many studies are focused on the development of high-tech materials with specific properties using industrial waste...

Owing to the limitations of visualization techniques in experimental studies and low-resolution numerical models based on computational fluid dynamics (CFD), the detailed behavior of oil droplets during microfiltration is not well understood. Hence, a high-resolution CFD model based on an in-house direct numerical simulation (DNS) code was constructed in this study to analyze the detailed dynamics of an oil-in-water (O/W) emulsion using a microfiltration membrane. The realistic microporous structure of commercial ceramic microfiltration membranes (mullite and α-alumina membranes) was obtained using an image processing technique based on focused ion beam scanning electron microscopy (FIB-SEM)...

Salts, organic materials, and hazardous materials can be found regularly in the effluent from a desalter unit of crude oil. These materials should be separated from the wastewater. Four kinds of inexpensive and innovative ceramic microfiltration membranes (mullite, mullite-alumina (MA 50%), mullite-alumina-zeolite (MAZ 20%), and mullite-zeolite (MZ 40%)) were synthesized in this research using locally available inexpensive raw materials such as kaolin clay, natural zeolite, and alpha-alumina powders. Analyses carried out on the membranes include XRD, SEM, void fraction, the average diameter of the pores, and the ability to withstand mechanical stress...

Efficient treatment of challenging oily emulsion wastewater can alleviate water pollution to provide more chances for water reuse and resource recovery. Despite their promising application potential, conventional porous ceramic membranes have challenging bottleneck issues such as high cost and insufficient permeance. This study presents a new strategy for highly efficient treatment of not only synthetic but real oily emulsions via unexpensive whisker-constructed ceramic membranes, exhibiting exceptional permeance and less energy input...

Treatment of hypersaline waters is a critical environmental challenge. Pervaporation (PV) desalination is a promising technique to address this challenge, but current PV membranes still suffer from challenging issues such as low flux and insufficient stability. Herein, we propose in situ nanoseeding followed by a secondary growth strategy to fabricate a high-quality stable metal-organic framework (MOF) thin membrane (UiO-66) for high-performance pervaporation desalination of hypersaline waters. To address the issue of membrane quality, a TiO2 nano-interlayer was introduced on coarse mullite substrates to favor the growth of a UiO-66 nanoseed layer, on which a well-intergrown UiO-66 selective membrane layer with thickness as low as 1 μm was finally produced via subsequent secondary growth...

The aim of the present study is to enhance the performance of a microbial fuel cell (MFC) design by making simple interventions. Specifically, terracotta "t" and mullite "m" ceramics are tested as membranes while carbon veil and carbon cloth are used as electrodes. In the case of "m" cylinders different dimensions are examined (m: ID 30 mm x height 11.5 mm; sm: ID 18 mm x height 18 mm). The units operated continuously with urine as the feedstock. The best performing is the sm type (60-100 μW), followed by the t type (40-80 μW) and the m type (20-40 μW)...

Support is a necessary foundation for ceramic membranes to achieve high performance. Finding the optimum balance between high performance and low cost is still a significant challenge in the fabrication of ceramic supports. In this study, low-cost fly ash-based ceramic supports with enhanced performance were prepared by the addition of bauxite. The pore structure, mechanical strength, and shrinkage of fly ash/bauxite supports could be tuned by optimizing the bauxite content and sintering temperature. When the sintering temperature and bauxite content were controlled at 1300 °C and 40 wt%, respectively, the obtained membrane supports exhibited a high pure water permeance of approximately 5...

Recently, the coupling of biofuel fermentation broths and pervaporation has been receiving increasing attention. Some challenges, such as the destructive effects of constituents of the real fermentation broth on the membrane performances, the lethal effects of the membrane surface chemical modifiers on the microorganisms, and being expensive, are against this concept. For the first time, a continuous study on the one-step and low-cost preparation of superhydrophobic membranes for bioethanol separation is made to address these challenges...

Dense and good catalytic performance TS-1 zeolite membranes were rapidly prepared on porous mullite support by secondary hydrothermal synthesis. The properties of seed crystals were very important for the preparation of high-catalytic performance TS-1 zeolite membranes. Influences of seed crystals (Ti/Si ratios, size, morphology, and zeolites concentration of the seed suspension) on the growth and catalytic property of TS-1 zeolite membranes were investigated in details. High Ti/Si ratio, medium-size, and morphology of the seed crystals were critical for preparing the high-performance TS-1 zeolite membrane...

In the present work, ceramic-supported chitosan hybrid membranes were prepared for the pervaporation dehydration of ethanol. Mullite and combined mullite-alumina (50% alumina content) tubular low-cost ceramic supports were fabricated, and their influence on membrane performance was compared to a commercial α-alumina support. The membrane preparation parameters were different ceramic supports and the concentration of chitosan solution (varying from 2 wt.% to 4 wt.%). The supports and hybrid membranes were characterized by field emission scanning electron microscopy (FE-SEM) and contact angle measurements...

Continuous and high silica SSZ-13 zeolite membranes were prepared on porous mullite supports from high SiO₂/Al₂O₃ ratio or aluminum-free precursor synthesis gel. Single gas permeance (CO₂ and CH₄) of the high silica SSZ-13 zeolite membrane was decreased with the SiO₂/Al₂O₃ ratio in the precursor synthesis gel, while the ideal CO₂/CH₄ selectivity of the membrane was gradually increased. Moreover, effects of synthesis conditions (such as H₂O/SiO₂ and RNOH/SiO₂ ratios of precursor synthesis gel, crystallization time) on the single gas permeance performance of high silica SSZ-13 zeolite membranes were studied in detail...

Two ceramic stacks, terracotta (t-stack) and mullite (m-stack), were developed to produce energy when fed with neat undiluted urine. Each stack consisted of twelve identical microbial fuel cells (MFCs) which were arranged in cascades and tested under different electrical configurations. Despite voltage reversal, the m-stack produced a maximum power of 800 μW whereas the t-stack produced a maximum of 520 μW after 62.6 h of operation. Moreover, during the operation, both systems were subject to blockage possibly due to struvite...

In this work, aluminum and iron existing in coal fly ash were extracted by the method of hydrochloric acid leaching. Effects of solid-liquid ratio, reaction temperature, reaction time, acid concentration, and raw ash mesh on recovery efficiencies of Al2 O3 and Fe2 O3 were investigated. X-ray diffraction analysis indicated that anhydrite, hematite, mullite and quartz were the dominant minerals in the raw fly ash sample. X-ray fluorescence technique was applied to determine the mass fractions of chemical components in the raw ash and leached residues, while the concentrations of Al2 O3 and Fe2 O3 in leaching solutions were measured by titration method...

In this research, four types of low cost and high performance ceramic microfiltration (MF) membranes have been employed in an in-line adsorption-MF process for oily wastewater treatment. Mullite, mullite-alumina, mullite-alumina-zeolite and mullite-zeolite membranes were fabricated as ceramic MF membranes by low cost kaolin clay, natural zeolite and α-alumina powder. Powdered activated carbon (PAC) and natural zeolite powder in concentrations of 100-800 mg L-1 were used as adsorbent agent in the in-line adsorption-MF process...

Oil-in-water (O/W) emulsion is considered to be difficult to treat. In this work, a low-cost multi-layer-structured mullite-titania composite ceramic hollow fiber microfiltration membrane was fabricated and utilized to efficiently remove fine oil droplets from (O/W) emulsion. In order to reduce membrane cost, coal fly ash was effectively recycled for the first time to fabricate mullite hollow fiber with finger-like and sponge-like structures, on which a much more hydrophilic TiO2 layer was further deposited...

Microbial fuel cells (MFCs) made with different types of ceramic membranes were investigated to find a low-cost alternative to commercially available proton exchange membranes. The MFCs operated with fresh human urine as the fuel. Pyrophyllite and earthenware produced the best performance to reach power densities of 6.93 and 6.85 W m(-3), respectively, whereas mullite and alumina achieved power densities of 4.98 and 2.60 W m(-3), respectively. The results indicate the dependence of bio-film growth and activity on the type of ceramic membrane applied...

In order to reduce environment risk of zinc, a spinel-based porous membrane support was prepared by the high-temperature reaction of zinc and bauxite mineral. The phase evolution process, shrinkage, porosity, mechanical property, pore size distribution, gas permeation flux and microstructure were systematically studied. The XRD results, based on a Zn/Al stoichiometric composition of 1/2, show a formation of ZnAl2O4 structure starting from 1000°C and then accomplished at 1300°C. For spinel-based composite membrane, shrinkage and porosity are mainly influenced by a combination of an expansion induced by ZnAl2O4 formation and a general densification due to amorphous liquid SiO2...

Porous mullite ceramic supports for filtration membrane were successfully fabricated via recycling of coal gangue and bauxite at sintering temperatures from 1100 to 1500°C with corn starch as pore-forming agent. The dynamic sintering behaviors, phase evolution, shrinkage, porosity and pore size, gas permeation flux, microstructure and mechanical property were systematically studied. A unique volume-expansion stage was observed at increased temperatures from 1276 to 1481°C caused by a mullitization-crystal-growth process...

In this paper, results of an experimental and modeling of separation of oil from industrial oily wastewaters (desalter unit effluent of Seraje, Ghom gas wells, Iran) with mullite ceramic membranes are presented. Mullite microfiltration symmetric membranes were synthesized from kaolin clay and alpha-alumina powder. The results show that the mullite ceramic membrane has a high total organic carbon and chemical oxygen demand rejection (94 and 89%, respectively), a low fouling resistance (30%) and a high final permeation flux (75 L/m2 h)...