Recycling of coal fly ash for fabrication of elongated mullite rod bonded porous SiC ceramic membrane and its application in filtration

Das, Debasish; Kayal, Nijhuma; Gabriel, Antonio Marsola; Daniel, Gonçalves Parra Filho; Innocentini, M. D. M.

doi:10.1016/j.jeurceramsoc.2020.01.034

Cited by 95 publications

(30 citation statements)

References 51 publications

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“…24 In further studies, the application of one dimensional multi-walled carbon nanotubes (MWCNTs) and mullite rods, owing to their outstanding thermal and mechanical properties at elevated temperatures, attracted much attention. [28][29][30][31][32][33][34][35][36][37] For instance, the strength and toughness of Al 2 O 3 -C refractories can be improved by using a liquid phenolic resin binder together with a nickel nitrate (Ni(NO 3 ) 2 ⋅6H 2 O) catalyst inducing the formation of MWCNTs in the matrix. 30,33 It was also reported that transition metal oxides including NiO and Fe 2 O 3 not only helped reduce the temperature of mullite formation, but had an important influence on the morphology of mullite rods and then enhanced the strength of Al 2 O 3 -C refractories.…”

Section: Introductionmentioning

confidence: 99%

“…Moreover, highly‐reactive expanded graphite promoted indeed the formation of SiC whiskers with high aspect ratio in the matrix and a higher strength was obtained 24 . In further studies, the application of one dimensional multi‐walled carbon nanotubes (MWCNTs) and mullite rods, owing to their outstanding thermal and mechanical properties at elevated temperatures, attracted much attention 28–37 . For instance, the strength and toughness of Al 2 O 3 ‐C refractories can be improved by using a liquid phenolic resin binder together with a nickel nitrate (Ni(NO 3 ) 2 ·6H 2 O) catalyst inducing the formation of MWCNTs in the matrix 30,33 .…”

Section: Introductionmentioning

confidence: 99%

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Enhanced mechanical properties of lightweight Al₂O₃‐C refractories reinforced by combined one‐dimensional ceramic phases

Chen

Yan

Schafföner

et al. 2021

Int J Applied Ceramic Tech

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We prepared a new lightweight Al2O3‐C refractory material with a higher strength by using microporous corundum aggregates instead of dense tabular corundum aggregates, which was reinforced by in situ formed SiC whiskers, multi‐walled carbon nanotubes (MWCNTs), and mullite rods. A comparative study of the microstructure, mechanical properties, and fracture behavior was carried out for dense and lightweight Al2O3‐C refractories coked at 1200°C and 1400°C, respectively. By using the microporous corundum aggregates, a better aggregate/matrix interface bonding and an optimized distribution of SiC whiskers were obtained. The SiC whiskers formed inside the microporous corundum aggregates and simultaneously in the matrix by a vapor‐solid reaction mechanism, resulting in an enhancement at the microporous aggregate/matrix interface. Furthermore, the in situ formed MWCNTs and well‐developed mullite rods at 1200°C in the matrix also contributed to the better interface structure. Thus, due to the improved microporous aggregate/matrix interface, the crack propagation along the aggregate/matrix interface was suppressed, resulting in an increased crack propagation within the aggregates. Consequently, the synergy between microporous corundum aggregates and combined one‐dimensional ceramic phases caused a lower bulk density but a markedly higher strength, a higher fracture energy, and a higher toughness of lightweight Al2O3‐C refractories compared to the dense ones. Overall, our study allows to overcome the traditional concept that a higher strength of refractories is reached by a higher density.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Enhanced mechanical properties of lightweight Al₂O₃‐C refractories reinforced by combined one‐dimensional ceramic phases

Chen

Yan

Schafföner

et al. 2021

Int J Applied Ceramic Tech

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“…When sintered in the air, SiC is oxidized into SiO2, which covers around SiC particles and bonds them together like sintering due to the viscous flow of the oxidation-derived SiO2 [22]. However, cristobalite undergoes a phase transition during cooling accompanied with around 6.4 vol% volume change, which tends to introduce cracks and lower the strength of SiC ceramics.…”

Section: Introductionmentioning

confidence: 99%

“…Since mullite (3Al2O3•2SiO2) exhibits a similar thermal expansion coefficient to SiC [24], better mechanical properties, good oxidation/corrosion resistance and thermal stability [25,26], aluminium sources are introduced to react with the oxidation-derived SiO2 and form mullite phase. Aluminium source includes alumina [27][28][29], Kaolin [30], aluminium hydroxide [31,32], bauxite [33], fly ash [22,34] and aluminium isopropoxide [35].…”

Section: Introductionmentioning

confidence: 99%

Effects of Composite Sintering Additives: Al(OH)3+Y2O3+CaF2 on the Performance of Porous Mullite Oxide-Bonded SiC Ceramics

Chang

Liu

et al. 2021

Preprint

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A composite sintering additive system: Al(OH)3+Y2O3+CaF2 was proposed for porous mullite oxide-bonded SiC ceramics. Small variations of sintering additives have significant influences on the phase composition, pore shape/size, density and flexural strength. Samples sintered at 1550 ℃ for 4 h in the air atmosphere realized both good mullite densification and no detectable cristobalite phase, which was difficult to be achieved at the same time. Besides, the composite sintering additive system also promoted the formation of columnar shape mullite, which acts as a reinforcement. Flexural strength as high as 108 MPa was achieved at an apparent porosity of 40.3 vol%, which is higher than that sintered by SPS technique. Moreover, those additives also act as pore formers determining the shape and size of pores. Around 8.9 µm strip-like, 11.8 µm continuous channel-like and 4.1 µm irregular pores were obtained for Al(OH)3, Al(OH)3-Y2O3 and Al(OH)3-Y2O3-CaF2 added samples, respectively. Corresponding phase evolution, sintering mechanisms and pore formation models were established. This work provides a simple way to modify the phase, pore size/shape, and strength of mullite oxide-bonded porous SiC ceramics by properly selecting sintering additives without any additional pore formers.

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“…Porous silicon carbide (SiC) ceramics possess a unique combination of desirable properties, such as excellent high temperature strength, high chemical stability, high thermal shock stability, and outstanding oxidation resistance [1][2] . Light and porous SiC structures are of interest for a number of advanced technological applications, such as hot-gas or molten-metal filters, catalyst supports and others [3][4][5] .…”

mentioning

confidence: 99%

Strong SiC Porous Ceramic Obtained by Sintering of Reticulated Aligned SiC Nanowires

Zhu¹,

Hu²,

Yang³

et al. 2021

Journal of Inorganic Materials

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High strength SiC porous ceramic with reticular pore structure is assembled by cross-lamination of layers comprised by aligned SiC nanowire (SiCNWs) struts printed through direct ink writing. SiCNWs networks exhibit a structure with highly interconnected porosity and an architecture formed by aligned SiCNWs struts. The effects of sintering temperature on the structures, phase evolutions and mechanical properties were studied. The high aspect ratio of SiCNWs was kept well at sintering temperature lower than 1900 ℃. The bulk density, porosity and median pore diameter of aligned SiCNWs porous ceramics sintered at 1850 ℃ were 1.49 g/cm 3 , 54.6% and ~1 μm, respectively. Due to the effect of orientation and high strength of SiC nanowire struts, compressive strength of (245.5±0.7) MPa is achieved.

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Recycling of coal fly ash for fabrication of elongated mullite rod bonded porous SiC ceramic membrane and its application in filtration

Cited by 95 publications

References 51 publications

Enhanced mechanical properties of lightweight Al₂O₃‐C refractories reinforced by combined one‐dimensional ceramic phases

Enhanced mechanical properties of lightweight Al₂O₃‐C refractories reinforced by combined one‐dimensional ceramic phases

Effects of Composite Sintering Additives: Al(OH)3+Y2O3+CaF2 on the Performance of Porous Mullite Oxide-Bonded SiC Ceramics

Strong SiC Porous Ceramic Obtained by Sintering of Reticulated Aligned SiC Nanowires

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Recycling of coal fly ash for fabrication of elongated mullite rod bonded porous SiC ceramic membrane and its application in filtration

Cited by 95 publications

References 51 publications

Enhanced mechanical properties of lightweight Al2O3‐C refractories reinforced by combined one‐dimensional ceramic phases

Enhanced mechanical properties of lightweight Al2O3‐C refractories reinforced by combined one‐dimensional ceramic phases

Effects of Composite Sintering Additives: Al(OH)3+Y2O3+CaF2 on the Performance of Porous Mullite Oxide-Bonded SiC Ceramics

Strong SiC Porous Ceramic Obtained by Sintering of Reticulated Aligned SiC Nanowires

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Enhanced mechanical properties of lightweight Al₂O₃‐C refractories reinforced by combined one‐dimensional ceramic phases

Enhanced mechanical properties of lightweight Al₂O₃‐C refractories reinforced by combined one‐dimensional ceramic phases