Honeycomb Ceramic Body with Titania Intermediate Layer
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Solution Overview
Problem
Conventional honeycomb shaped ceramic substrates with zeolite membranes suffer from strength deterioration under high temperature alkali conditions, and have high firing temperatures and costs, with existing solutions not addressing strength issues or shape influences.
Innovation Solution
A honeycomb shaped porous ceramic body using titania as an inorganic bonding material in an intermediate layer, with a zeolite membrane formed through hydrothermal synthesis, maintains strength and includes an alumina surface layer for enhanced durability and separation performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional honeycomb shaped ceramic substrates are used for zeolite membrane formation, then the substrate can be formed, but the strength deteriorates under high temperature alkali conditions
Solution Approach 1:
An intermediate layer made of alumina powder and inorganic bonding material is introduced between the honeycomb shaped porous ceramic substrate and the zeolite separation layer. This intermediate layer acts as a protective barrier that prevents direct contact between the alkali synthesis gel and the substrate, thereby preventing strength deterioration while allowing the zeolite membrane to be successfully formed on its surface
Solution Approach 2:
The substrate is constructed as a composite structure combining the honeycomb shaped porous ceramic body with an intermediate layer of alumina and inorganic bonding material. This composite structure provides both the mechanical support of the substrate and the chemical resistance of the alumina intermediate layer against alkali conditions
2Strength
If high firing temperature is used to form the substrate, then the substrate strength is improved, but the manufacturing cost increases
Solution Approach 1:
The firing temperature parameter is optimized to a specific range of 1000°C to 1400°C, which is sufficient to achieve the required substrate strength and form the intermediate layer without requiring excessively high temperatures. This parameter optimization reduces energy consumption and manufacturing costs while maintaining adequate substrate performance
3Productivity
If the membrane area is enlarged to improve permeation performance, then the separation performance is maintained, but the device complexity increases
Solution Approach 1:
The membrane area is enlarged by extending the length of the honeycomb shaped porous ceramic body in the axial direction rather than increasing the diameter. This dimensional approach allows achieving high permeation performance while maintaining a compact cross-sectional footprint and avoiding excessive device complexity
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 ceramic body exhibits improved strength and durability, maintaining internal pressure breaking strength of 16 MPa or more, even under alkali conditions, and supports high permeation flow rates with reduced manufacturing costs.
Implementation Method 1
at least a part of the intermediate layer has a structure in which aggregate particles are bonded to one another by a component of an inorganic bonding material
Implementation Method 2
a permeation flow rate is preferably increased by applying a high pressure during operation
Implementation Method 3
In the honeycomb shaped ceramic separation membrane structure, a permeation flow rate is preferably increased by applying a high pressure during operation. Particularly, in the ultrafiltration membrane, the gas separation membrane and the reverse osmosis membrane, a permeation coefficient of the separation membrane is small
Implementation Method 4
a porous substrate whose outer shape is columnar and which has therein a large number of parallel through channels (referred to as cells) formed in an axial direction
Data Source
Figure 1
Figure 2
Figure 3~4B
AI summary
An object of the present invention is to provide a honeycomb shaped porous ceramic body in which a strength deteriorates less than before after a separation layer is formed, a manufacturing method for the porous ceramic body, and a honeycomb shaped ceramic separation membrane structure. A honeycomb shaped porous ceramic body 9 includes a honeycomb shaped substrate 30 and an intermediate layer. At least a part of the intermediate layer of the honeycomb shaped porous ceramic body 9 has a structure in which aggregate particles are bonded to one another by a component of an inorganic bonding material. The inorganic bonding material is titania.