Honeycomb Ceramic Membrane Strength Optimization
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Solution Overview
Problem
Conventional honeycomb-shaped ceramic separation-membrane structures experience strength reduction when forming a zeolite membrane, particularly in high-temperature alkali conditions, and have high production costs due to high firing temperatures.
Innovation Solution
The honeycomb-shaped ceramic separation-membrane structure is designed with a specified base material thickness and intermediate layer thickness, along with a zeolite membrane formed using a hydrothermal synthesis method, to minimize strength reduction and maintain structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a zeolite membrane is formed on a conventional honeycomb-shaped ceramic base material, then separation performance is improved, but strength is reduced in high-temperature alkali conditions
Solution Approach 1:
The invention uses a composite base material consisting of alumina (80-95 wt%) and silica (5-20 wt%) to form a honeycomb-shaped ceramic structure that supports the zeolite membrane. This composite structure maintains high strength in high-temperature alkali conditions while enabling effective separation performance through the integrated zeolite membrane layer.
2Strength
If high firing temperature is used to form the ceramic base material, then mechanical strength and durability are improved, but production cost increases
Solution Approach 1:
The invention optimizes the chemical composition parameters of the base material by specifying alumina content at 80-95 wt% and silica content at 5-20 wt%, which enables the ceramic to achieve high mechanical strength and durability at reduced firing temperatures, thereby lowering production costs while maintaining performance.
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 structure achieves higher internal pressure fracture strength and reduced strength loss during zeolite membrane formation, while also lowering production costs by optimizing the base material and intermediate layer ratios.
Implementation Method 1
a separation layer (zeolite membrane) having a small pore diameter is formed on the inside wall faces forming the cells
Implementation Method 2
it is necessary to make the membrane area (area of the separation membrane) large in order to improve water permeability
Data Source
Figure 1
Figure 2~3
Figure 4A~4B
AI summary
The present invention aims to provide a honeycomb-shaped ceramic porous body where the strength reduction upon forming a separation layer is less than conventional porous bodies. The ceramic porous body (9) is provided with a honeycomb-shaped base material (30) and an intermediate layer. At least a part of the ceramic porous body (9) has a structure where aggregate particles are bonded to one another by an inorganic bonding material component. In the ceramic porous body (9), the intermediate layer thickness, which is the thickness of the intermediate layer, is 100 µm or more and 500 µm or less, the base material thickness at the shortest portion between the cells, but excluding the intermediate layer and the separation layer is 0.51 mm or more and 1.55 mm or less, and the ratio of the base material thickness to the intermediate layer thickness is 2.5 or more.