Porous mullite-bonded SiC filters prepared by foaming-sol-gel-tape casting for high-efficiency hot flue gas filtration

Fabrication of SiC Porous Ceramics by Foaming Method

In this work, hierarchically porous SiC ceramics were prepared via the foaming method. Porous ceramics with tunable, uniform, and bimodal pore structures were successfully fabricated in a facile way. The formation mechanisms of the 1st and 2nd modal macropores are the H₂O₂ foaming process and SiC particle overlap, respectively. The effect of pore-foaming agent amount, foaming temperature, and surfactant was investigated. According to the results, with increasing H₂O₂ amount, the porosity, pore size, and interconnectivity of the 1st modal pores increased, whereas bulk density and strength decreased. The porosity increased while the strength decreased as the foaming temperature increased. Surfactants increased pore interconnectivity and porosity. When the foaming temperature was 85 °C, and the addition of H₂O₂ was 5 wt.%, the porosity, bulk density, flexural strength, and compressive strength were 56.32%, 2.8301 g/cm³, 11.94 MPa, and 24.32 MPa, respectively. Moreover, SiC porous ceramics exhibited excellent corrosion resistance to acids and alkalis.

Recent Progress in Silicon Carbide-Based Membranes for Gas Separation

The scale of research for developing and applying silicon carbide (SiC) membranes for gas separation has rapidly expanded over the last few decades. Given its importance, this review summarizes the progress on SiC membranes for gas separation by focusing on SiC membrane preparation approaches and their application. The precursor-derived ceramic approaches for preparing SiC membranes include chemical vapor deposition (CVD)/chemical vapor infiltration (CVI) deposition and pyrolysis of polymeric precursor. Generally, SiC membranes formed using the CVD/CVI deposition route have dense structures, making such membranes suitable for small-molecule gas separation. On the contrary, pyrolysis of a polymeric precursor is the most common and promising route for preparing SiC membranes, which includes the steps of precursor selection, coating/shaping, curing for cross-linking, and pyrolysis. Among these steps, the precursor, curing method, and pyrolysis temperature significantly impact the final microstructures and separation performance of membranes. Based on our discussion of these influencing factors, there is now a good understanding of the evolution of membrane microstructures and how to control membrane microstructures according to the application purpose. In addition, the thermal stability, oxidation resistance, hydrothermal stability, and chemical resistance of the SiC membranes are described. Due to their robust advantages and high separation performance, SiC membranes are the most promising candidates for high-temperature gas separation. Overall, this review will provide meaningful insight and guidance for developing SiC membranes and achieving excellent gas separation performance.