Materials and Applications for Low-Cost Ceramic Membranes

Abstract

In water treatment applications, the use of ceramic membranes is associated with numerous advantages relative to polymer-based filtration systems. High-temperature stability, fouling resistance, and low maintenance requirements contribute to lower lifecycle costs in such systems. However, the high production costs of most commercially available ceramic membranes, stemming from raw materials and processing, are uneconomical for such systems in most water treatment applications. For this reason, there is a growing demand for new ceramic membranes based on low-cost raw materials and processes. The use of unrefined mineral feedstocks, clays, cement, sands, and ash as the basis for the fabrication of ceramic membranes offers a promising pathway towards the obtainment of effective filtration systems that can be economically implemented in large volumes. The design of effective ceramic filtration membranes based on low-cost raw materials and energy-efficient processes requires a balance of pore structure, mass flow, and robustness, all of which are highly dependent on the composition of materials used, the inclusion of various pore-forming and binding additives, and the thermal treatments to which membranes are subjected. In this review, we present recent developments in materials and processes for the fabrication of low-cost membranes from unrefined raw materials, including clays, zeolites, apatite, waste products, including fly ash and rice husk ash, and cement. We examine multiple aspects of materials design and address the challenges relating to their further development.

Preparation of a Zirconia-Based Ceramic Membrane and Its Application for Drinking Water Treatment

“…The clay consisted mainly of aluminum silicate (Al 2 SiO 5 ), intended for the manufacture of the tubular microporous support. The method of tubular support preparation can be summarized in the following steps [28,29]:…”

Review on Polymeric, Inorganic, and Composite Materials for Air Filters: From Processing to Properties

“…Uniaxial or hydrostatic pressing and subsequent sintering of ceramic powders, such as SiC, Al 2 O 3 , MgO, or low-cost ceramic materials with sacrificial pore-forming agents, e.g., fugitive organic materials, is a simple and common processing technique to obtain granular ceramic materials that can be used as air filters. [200][201][202] Metallic air filters, e.g., made from nickel, were also fabricated by uniaxial pressing. [203] Air filters produced by pressing commonly have pore sizes within a few micrometers and porosities up to 70%, see Table 7.…”

Influence of the Natural Zeolite Particle Size Toward the Ammonia Adsorption Activity in Ceramic Hollow Fiber Membrane

“…For example, bauxite contains a high amount of alumina; thus, it requires high sintering temperature to be produced as a ceramic membrane [18]. Meanwhile, the usage of the fly ash may lead to the production of porous materials that contain various phases including mullite, anorthite, and cordierite [19]. The membranes of pure fly ash typically possess low mechanical strength and need additives to enhance their durability [20].…”