3D-Printed Ceramic Membrane With Controlled Si/Al and Porosity
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Solution Overview
Problem
Existing methods for producing zeolites from coal ash are complex and do not effectively control the Si/Al ratio, particle size, and porosity, and there is a lack of technologies to utilize coal ash waste for manufacturing ceramic membranes with controlled silicon content, thickness, and hydrophilicity/hydrophobicity.
Innovation Solution
A method involving hydrothermal synthesis of hydroxy-sodalite zeolite from coal fly ash and coal bottom ash, followed by 3D printing of ceramic membranes using coal ash-derived materials, allowing control over silicon content, thickness, and hydrophilicity/hydrophobicity, utilizing Solvent-based Slurry Stereolithography for precise layer-by-layer fabrication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional synthesis methods are used to produce zeolites from coal ash, then zeolite production is achieved, but the process complexity increases and control over Si/Al ratio and particle size is insufficient
Solution Approach 1:
The patent changes the synthesis parameters by using hydrothermal treatment at specific temperatures (100-200°C) and pH conditions (pH 10-12) to precisely control the Si/Al ratio of zeolite products. By adjusting reaction temperature, time, and alkaline agent dosage, the method achieves targeted Si/Al ratios (1.0-2.5) and controlled particle sizes, resolving the contradiction between manufacturing precision and process complexity
Solution Approach 2:
The patent replaces complex mechanical mixing and manual processing with hydrothermal synthesis methodology. The hydrothermal process automatically controls particle formation and size distribution through temperature and pressure conditions, eliminating the need for complex mechanical intervention while achieving precise control over zeolite properties
2Manufacturing precision
If conventional ceramic membrane manufacturing is used, then membrane production is achieved, but control over thickness, porosity, and hydrophilicity is limited
Solution Approach 1:
The patent applies local quality by creating ceramic membranes with spatially varying properties through controlled drying and sintering processes. Different regions of the membrane can have different porosity, thickness, and hydrophilicity levels by adjusting drying rates and sintering conditions, allowing precise control over local membrane characteristics while maintaining overall manufacturing simplicity
Solution Approach 2:
The patent uses a universal slurry formulation containing coal ash particles, binding agents, and pore-forming agents that can produce membranes with multiple desired properties (thickness, porosity, hydrophilicity) through a single manufacturing process. The slurry composition and processing parameters are optimized to simultaneously control multiple membrane characteristics, simplifying the manufacturing process while achieving precise control
3Loss of energy
If coal ash is disposed of traditionally, then waste removal is achieved, but environmental burden increases and resource waste occurs
Solution Approach 1:
The patent converts harmful coal ash waste into beneficial ceramic membrane materials with valuable properties. The coal ash particles serve as precursors for zeolite formation and ceramic membrane fabrication, transforming an environmental hazard into a functional material. This approach simultaneously reduces environmental burden and creates economic value, achieving both waste reduction and resource utilization
Solution Approach 2:
The patent recovers valuable silicon and aluminum components from coal ash that would otherwise be discarded. Through hydrothermal treatment and ceramic processing, the coal ash is transformed into zeolite and ceramic membranes with controlled properties. The process recovers up to 80-90% of the silicon and aluminum content in useful forms, eliminating waste while creating valuable products
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method produces ceramic membranes with adjustable properties suitable for industrial applications, including wastewater treatment and microbial fuel cells, providing a cost-effective and environmentally friendly solution for coal ash recycling.
Implementation Method 1
the zeolite is synthesized from coal fly ash and/or coal bottom ash through a hydrothermal method at a lower temperature without stirring
Implementation Method 2
utilizing Solvent-based Slurry Stereolithography for precise layer-by-layer fabrication
Data Source
AI summary
The present disclosure provides a ceramic membrane prepared by 3D printing technology, comprising Al2O3·2SiO2 and/or Na8[AlSiO4]6(OH)2, or hydrates thereof. The overall thickness of the ceramic membrane is from 0.01 cm to 1.5 cm, and the ceramic membrane contains 70 wt % to 85 wt % of silicon. According to the ceramic membrane and the preparation method thereof of the present disclosure, the ceramic membrane may operate under harsh chemical conditions and may be widely applied in various applications such as wastewater treatment and microbial fuel cells.