Multilayered Ceramic Filtration Element with Narrow Pore Distribution
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Solution Overview
Problem
Ceramic filtration membranes used in nanofiltration and ultrafiltration face challenges such as high fouling rates, mechanical instability, and defects leading to inefficient filtration performance and reduced water quality, particularly due to the sol-gel process which results in a high amorphous phase and low resistance to corrosive media.
Innovation Solution
A multilayered ceramic filtration element is developed by consecutively applying suspensions of ceramic compounds of varying sizes to a ceramic support structure, avoiding the sol-gel process, which results in a membrane with a narrow pore size distribution, low defect rate, and enhanced chemical and mechanical stability, allowing for improved retention of chemicals and reduced fouling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If sol-gel process is used to manufacture oxide ceramic filtration membranes, then membrane layers with small pore sizes are formed, but the membranes contain high portion of amorphous phase reducing resistance against corrosive media and mechanical abrasion
Solution Approach 1:
The invention changes the manufacturing parameter from sol-gel process to direct ceramic particle deposition process. This parameter change eliminates the formation of amorphous phase while achieving the desired small pore sizes, thereby simultaneously improving both manufacturing precision and reliability against corrosive media.
Solution Approach 2:
The invention uses composite ceramic structures combining crystalline ceramic particles with a porous support structure. This composite approach allows achieving small pore sizes through careful particle selection while maintaining high crystallinity and resistance against corrosive media, resolving the contradiction between pore size control and chemical stability.
2Reliability
If ceramic filtration membranes are used in nanofiltration and ultrafiltration, then filtration separation is achieved, but high fouling rates and mechanical instability occur
Solution Approach 1:
The invention employs specifically designed porous ceramic structures with controlled pore sizes, pore distributions, and surface characteristics. The porous structure is optimized to minimize fouling while maintaining effective filtration separation, addressing the contradiction between achieving good filtration performance and reducing membrane fouling.
3Productivity
If conventional ceramic membranes are used, then initial filtration performance is achieved, but permeate flux decreases due to membrane fouling and defects
Solution Approach 1:
The invention applies preliminary actions during membrane fabrication to minimize defect formation and optimize surface properties before the membrane is put into service. This includes careful control of particle deposition, sintering parameters, and surface treatment to create a fouling-resistant membrane that maintains high permeate flux over extended operational periods.
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 solution provides high permeability, durability, and efficient filtration performance with reduced blockages and maintenance needs, maintaining high permeability and filtrate quality over multiple cycles, even under harsh conditions.
Implementation Method 1
consecutive application of suspensions comprising particles of at least one ceramic compound of different sizes
Implementation Method 2
continuous network of pores allowing liquids to pass through
Data Source
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AI summary
The present disclosure relates to a method of preparing ceramic filtration membranes with a low defect rate and improved filtration performances. The ceramic filtration membranes have a layered structure, wherein the layers are concerted to generate an improved filtration performance.