Porous Composite Oxide Material via Iron Reduction
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Solution Overview
Problem
Existing porous materials face challenges such as large pore diameters, contamination from additives, complex preparation procedures, high process costs, and difficulties in large-scale production, which hinder their efficiency and cost-effectiveness for diverse applications.
Innovation Solution
A porous material composed of a composite oxide body including calcium oxide, iron oxide, and silica with microchannel structures formed through a reduction reaction at temperatures below 1000°C, which creates main and branched channels with high aspect ratios, and a method for preparing this material without the need for pore-forming agents, reducing material costs and simplifying the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional pore-forming methods (liquid-phase method, powder sintering method, metal deposition method) are used, then porous materials can be produced, but the pore diameter becomes excessively large and contamination occurs from additives
Solution Approach 1:
The patent removes the harmful pore-forming agents (additives) from the system entirely. Instead of using external pore-forming chemicals that cause contamination, the invention uses the reduction of iron oxide particles within the composite oxide body itself to create pores, thereby extracting the harmful element while maintaining the desired porous structure.
Solution Approach 2:
The iron oxide particles within the composite oxide body serve dual functions: they are both structural components and pore-forming agents. During reduction, the iron oxide particles themselves transform into porous structures, eliminating the need for separate pore-forming additives and achieving self-service pore formation without contamination.
2Shape
If sintering aids or pore-forming agents are used, then porous structures can be formed, but the preparation procedure becomes complex and process cost increases
Solution Approach 1:
The patent merges the functions of structural material and pore-forming agent into a single composite oxide body. The iron oxide particles are integrated within the calcium oxide-silica matrix, combining structure and pore formation into one material system, thereby simplifying the preparation procedure by eliminating separate sintering aids and pore-forming agents.
Solution Approach 2:
The composite oxide body serves multiple functions simultaneously: it provides the structural framework, contains the pore-forming iron oxide particles, and undergoes reduction to create the final porous structure. This multi-functionality eliminates the need for multiple separate components and simplifies the overall preparation process.
3Quantity of substance
If conventional preparation methods are used, then porous materials can be produced, but the process cost becomes high and large-scale production is difficult
Solution Approach 1:
The patent changes the temperature parameter to below 1000°C, which is lower than conventional sintering temperatures. This parameter change reduces energy consumption and material volatility, thereby lowering process costs and facilitating large-scale production while maintaining the desired porous structure and avoiding excessive material consumption.
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 resulting porous material exhibits high porosity, specific surface area, and catalytic activity, suitable for various applications, with a cost-effective and environmentally friendly production process that avoids residual carbon contamination and complex preparation steps.
Implementation Method 1
performing a pore-forming process for at least once including a reduction reaction on composite oxide powder including calcium oxide, iron oxide and silica at a temperature of 1,000° C. or below 1,000° C., wherein the reduction reaction is carried out by contacting the composite oxide powder with a reducing gas stream
Data Source
AI summary
A porous material including a composite oxide body containing calcium oxide, iron oxide, and silica, and a plurality of inter-connecting microchannel structures is provided. A preparing method of porous material is further provided. With the inter-connecting microchannel structures of the porous material and the advantages of high porosity and large specific surface area, the porous material has a bright prospect in the fields of catalysts, filters, adsorption materials, and fuel carriers.