Polyhedral Alumina Ceramic Membrane Support Preparation
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Solution Overview
Problem
Current methods for preparing ceramic membrane supports are complex, costly, and result in unstable performance due to high sintering temperatures, difficulty in achieving high porosity and strength, and the use of spherical alumina powders that are challenging to sinter and have low porosity.
Innovation Solution
A method involving pre-sintering aluminium hydroxide to produce low-temperature alumina, adding mineralizers, grinding, and calcining to achieve polyhedral alumina powders with specific particle size distributions, which are then mixed with binders and sintered to create a high-porosity, high-strength ceramic membrane support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If spherical alumina powders are used to prepare ceramic membrane support, then the mechanical strength is improved, but the porosity decreases and sintering becomes difficult
Solution Approach 1:
The patent applies asymmetry by changing the particle shape from spherical to polyhedral alumina powders. This asymmetric shape modification allows particles to interlock better during sintering, improving both mechanical strength and porosity simultaneously, resolving the contradiction between strength and manufacturability
Solution Approach 2:
The patent changes the particle size parameter distribution by using a mixed size system (20-30 μm coarse particles and 3-5 μm fine particles) instead of uniform spherical particles. This parameter modification enables better packing density and porosity control while maintaining high strength
2Strength
If high sintering temperature above 1750°C is used, then the mechanical strength is improved, but the equipment complexity and cost increase
Solution Approach 1:
The patent changes the sintering temperature parameter from above 1750°C to 1600-1700°C by modifying the alumina powder characteristics (polyhedral shape and size distribution). This parameter shift reduces the thermal load on equipment while achieving comparable or superior mechanical properties
Solution Approach 2:
The patent performs preliminary particle shape preparation and size distribution control before sintering. The polyhedral shape and mixed size distribution are prepared in advance, which facilitates sintering at lower temperatures by improving particle contact and reducing sintering activation energy requirements
3Ease of manufacture
If rod-shaped corundum or alumina powders are used, then the sintering process is simplified, but the porosity and flux decrease
Solution Approach 1:
The patent uses polyhedral alumina powders with asymmetric shapes that have flat surfaces and sharp edges, unlike rod-shaped particles. This asymmetric geometry provides better interparticle contact areas, facilitating sintering while maintaining high porosity and flux properties
4Strength
If foreign commercial preparation methods are used, then the mechanical strength is improved, but the process complexity and cost increase
Solution Approach 1:
The patent segments the alumina powder production into distinct stages: pre-sintering at lower temperature, followed by controlled calcination to achieve polyhedral shape, and finally size classification. This segmentation simplifies each individual step while achieving the desired particle characteristics and reducing overall process complexity
Solution Approach 2:
The patent modifies key process parameters including pre-sintering temperature (lower than conventional methods), calcination atmosphere, and particle size distribution. These parameter changes simplify the preparation process while producing polyhedral particles with superior sintering properties
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 simplifies the process, reduces costs, and produces ceramic membrane supports with improved porosity, strength, and corrosion resistance, enabling easier sintering and industrial application.
Implementation Method 1
taking aluminium hydroxide, produced through a carbon decomposing process by a sintering method, as a raw material, pre-sintering the aluminium hydroxide, and obtaining a low-temperature alumina product A
Implementation Method 2
adding a first amount of mineralizer into the product A, grinding after calcining the added product A till a particle size is in a range of 5-15 μm
Implementation Method 3
calcining after adding a second amount of mineralizer into the mixed product B, obtaining a α-alumina product C
Implementation Method 4
sintering, and finally obtaining a porous alumina support
Data Source
AI summary
A preparation method of a ceramic membrane support is disclosed. Take aluminum hydroxide, produced through a carbon decomposing process by a sintering method, as a raw material, pre-sinter the aluminum hydroxide, and obtain a low-temperature alumina product A; add a first amount of mineralizer into the product A, grind after calcining the added product A, and obtain a α-alumina product B; mix the product B with Al2O3.nH2O, calcine after adding a second amount of mineralizer into the mixed product B, and obtain a α-alumina product C; grind, scatter and grade the calcined and heat-preserved α-alumina product C, and obtain polyhedral alumina powders; mix the polyhedral alumina powders, water, humectant and dispersant and then sinter, and finally obtain the porous alumina support. The prepared support is easy to be sintered, is high in alumina purity, is good in corrosion resistance, and is improved in porosity and flux.