Ceramic membranes technique

The vast increase in the application of membranes has expanded our knowledge of fabrication of various types of membrane, such as organic and inorganic membranes. The inorganic membrane is frequently called a ceramic membrane. To fulfil the need of the market, ceramic membranes represent a distinct class of inorganic membrane. There are a few important parameters involved in ceramic membrane materials, in terms of porous structure, chemical composition and shape of the filter in use. In this research, zirconia-coated y-alumina membranes have been developed using the sol-gel technique. 

We have successfully developed a new inorganic ceramic membrane coated with zirconium and alumina. A thin film of alumina and zirconia unsupported membrane was also fabricated. The successful method developed was the sol-gel technique. 

Fig. 4. Configuration of a ceramic membrane reactor for partial oxidation of methane. The membrane tube, with an outside diameter of about 6.5 mm and a length of up to about 30 cm and a wall thickness of 0.25-1.20 mm, was prepared from an electronic/ionic conductor powder (Sr-Fe-Co-O) by a plastic extrusion technique. The quartz reactor supports the ceramic membrane tube through hot Pyrex seals. A Rh-containing reforming catalyst was located adjacent to the tube (57).

In this section a short introduction will be given on the synthesis of porous ceramic membranes by sol-gel techniques and anodization, carbon membranes, glass membranes and track-etch membranes. An extensive discussion will be given in Sections 2.3-2.S. 

Venkataraman, K., W. T. Choate, E. R. Torre, R. D. Husung and H. R. Batchu. 1988. Characterization studies of ceramic membranes A novel technique using a Coulter porometer. J. Membrane Sci. 39(3) 259-71. 

Hollow glass microbeads Porous ceramic membranes Microbeads coated by Ti02 particles Porous ceramic Ti02 and ZnO membranes prepared by sol-gel technique... 

During the last few years, ceramic- and zeolite-based membranes have begun to be used for a few commercial separations. These membranes are all multilayer composite structures formed by coating a thin selective ceramic or zeolite layer onto a microporous ceramic support. Ceramic membranes are prepared by the sol-gel technique described in Chapter 3 zeolite membranes are prepared by direct crystallization, in which the thin zeolite layer is crystallized at high pressure and temperature directly onto the microporous support [24,25],... 

The in situ membrane growth technique cannot be applied using the zeolite-based ceramic porous membrane as support, under hydrothermal conditions in a solution containing sodium hydroxide. The high pH conditions will cause membrane amorphization and lead to final dissolution. Therefore, we tried to synthesize an aluminophosphate zeolite such as AlP04-5 [105] over a zeolite porous ceramic membrane. For the synthesis of the AlP04-5-zeolite-based porous membrane composite, the in situ membrane growth technique [7,13,22] was chosen. Then, the support, that is, the zeolite-based porous ceramic membrane, was placed in contact with the synthesis mixture and, subsequently, subjected to a hydrothermal synthesis process [18]. The batch preparation was as follows [106] ... 

While dip coating and spin coating are used most often for making microporous ceramic membranes, the filtration technique for forming dynamic membranes can also be used [Okubo et al., 1991]. The filtration method is particularly suitable when the support does not have enough pore volume to supply sufficient slip particles at the support surface to form a layer of membrane. 

The smallest poie diameters of ceramic membranes that can be obtained consistently by the straight sol-gel process without any modification has been in the range of 2.5 to 3.0 nm. This minimum pore size obtainable is determined by the smallest size of the primary sol particles that can be crystallized and the consideration of the effect of subsequent calcination on the pore size. Stable, non-aggregated nuclei finer than S nm are very difficult to generate. To produce membranes via the sol-gel route that are smaller than 2.5-3.0 nm requires further modifications by such techniques as adsorption or precipitation in the pores as will be discussed in tk>n 3.4.1. 

Trocha and Koros [1994] applied a diffusion-controlled caulking procedure with colloidal silica to plug large pores or defects in ceramic membranes. An important feature of this proc ure is the proper selection of the colloid particle size to eliminate or reduce large, less selective pores while minimizing deposition in the small desirable pores. The technique has b n successfully proven with anodic alumina membranes (having the majority of the pores about 2(X) nm in diameter) using 10-20 nm silica colloids. 

This method has been applied to ceramic membranes (e.g., gamma-alumina membranes) and compared to other methods such as nitrogen adsorption/desorption and thermoporometry (to be discussed next) in Figure 4.13. It can be seen that the mean pore diameter measured by the three methods agrees quite well. The pore size distribution by permporometry, however, appears to be narrower than those by the other two techniques. Similar conclusions have been drawn regarding the comparison between permporometry and nitrogen adsorption/desorption methods applied to porous alumina membranes [Cao et al., 1993]. The broader pore size distribution obtained from nitrogen adsorption/desorption is attributable to the notion that the method includes the contribution of passive pores as well as active pores. Permporometry only accounts for active pores. 

Yeast can be separated from an ethanol fermentation broth by porous ceramic membranes with backflushing [Matsumoto et al., 1988]. Tubular alumina membranes with a nominal pore diameter of 1.6 pm were demonstrated to be effective for this application with a maximum permeate flux of 1,1(X) IVhr-m with backflushing. The permeate flux increases with increasing feed rale (or crossflow velocity) and TMP and with decreasing yeast concentration. Various backflushing techniques were investigated and the reverse flow of filtrate (instead of air) either by pressure from the permeate side... 

Forccd flow mode. Invertase, an enzyme, can be chemically immobilized to the surfaces of ceramic membrane pores by the technique of covalent bonding of silane-glutaraldehyde [Nakajima et al., 1989b]. The substrate (reactant), during the sucrose conversion process, enters the membrane reactor in a crossflow mode. Under suction from the other side of the membrane, the substrate flows into the enzyme-immobilized membrane pores where the bioconversion takes place. Both the product and the unreacted substrate indiscriminately pass through the membrane pores. Thus, no permselective properties are utilized in this case. The primary purpose of the membrane is to provide a well-engineered catalytic path for the reactant, sucrose. 

A new technique is under development for depositing metal onto a ceramic substrate (e.g., ceramic membrane) at room temperature. This ion vapor deposition process combines ion implementation and electron beam deposition [Anonymous, 1988]. The ceramic substrate is irradiated with argon or nitrogen ions while the metal is vaporized by an electron beam and deposited onto the ceramic surface. The ion implementation directs the metal to the surface to be joined. 

The porous structure of ceramic supports and membranes can be first described using the lUPAC classification on porous materials. Thus, macroporous ceramic membranes (pore diameter >50 nm) deposited on ceramic, carbon, or metallic porous supports are used for cross-flow microfiltration. These membranes are obtained by two successive ceramic processing techniques extrusion of ceramic pastes to produce cylindrical-shaped macroporous supports and slip-casting of ceramic powder slurries to obtain the supported microfiltration layer [2]. For ultrafiltration membranes, an additional mesoporous ceramic layer (2 nm<pore diameter <50 nm) is deposited, most often by the solgel process [11]. Ceramic nanofilters are produced in the same way by depositing a very thin microporous membrane (pore diameter <2 nm) on the ultrafiltration layer [4]. Two categories of micropores are distinguished the supermicropores >0.7 nm and the ultramicropores <0.7 nm. 

Microfiltration and ultrafiltration are the two main filtration techniques for which ceramic membranes have been widely used to date. As described in Section 6.2.1.2, MF and UF ceramic membranes exhibit macro- and mesoporous structure, respectively, which result from packing and sintering of ceramic particles. Liquid flow in such porous media is convective in nature and the simplest description of permeation flux, J, is given by the Darcy s equation [20] ... 

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