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The preparation and characterization of kaolin based ceramic membranes using styrofoam (STY) and sawdust (SD) as pore formers have been prepared by mechano-chemical synthesis using pressureless sintering technique with porogen content between (0–20) wt% by die pressing. Pellets were fired at 1150 °C and soaking time of 4 h. The membranes cast as circular disks were subjected to characterization studies to evaluate the effect of the sintering temperature and pore former content on porosity, density, water absorption and mechanical strength. Obtained membranes show effective porosity with maximum at about 43 and 47% respectively for membranes formulated with styrofoam and sawdust porogens but with a slightly low mechanical strength that does not exceed 19 MPa. The resultant ceramic bodies show a fine porous structure which is mainly caused by the volatilization of the porogens. The fabricated membrane exhibited high N 2 gas flux, hence, these membranes can be considered as efficient for potential application for gas separation by reason of the results shown in the gas flux tests. [ABSTRACT FROM AUTHOR]

The objective of this study was to prepare low-cost macroporous ceramic membranes using natural kaolin obtained from deposits in Nigeria and Ghana, and powdery high density polyethelene (PHDPE) as porogen agent. The ceramic membranes have been prepared with porogen content wt% between (0 and 20)% by die pressing. Pellets were fired at 1150 °C and soaking time of 4 h. The raw materials were characterized using TG/DTA, particle size distribution (PSD) and Zeta potential. The membranes cast as circular disks were subjected for characterization studies using XRD and SEM analysis. In a bid to correlate the physico-mechanical properties vis-à-vis pore former content, the effect of the sintering temperature and pore former (PHDPE) content on porosity, density, water absorption and mechanical strength were evaluated. The membrane corrosion resistance was found to be unaltered with experimental conditions. Obtained membranes showed good porosity with maximum at about 62% with a mechanical strength that does not exceed 18 MPa. These membranes can be considered as efficient regarding the results shown in the gas permeation tests at different sintering temperatures. A PHDPE percentage of 20% and a sintering temperature of 1150 °C were chosen as the optimum for gas permeation based on enlarged pore diameter of sintered membranes. [ABSTRACT FROM AUTHOR]

In this work, the suitability of using kaolin–styrofoam, sawdust, and high density polyethylene to produce porous ceramic bodies was experimentally investigated. The kaolin samples (raw and beneficiated) were characterized by the XRD, SEM, TGA/DSC and FTIR methods. Batch formulations of the samples including the kaolin and pore formers were formed into green bodies and fired to 1150 °C. The porosities of sintered bodies were calculated and gave the following: apparent porosity: 28.63%–67.13% for all the samples investigated. Samples with high density polyethylene (HDPE) pore formers showed minor surface cracks after firing, but exhibited the highest porosity levels while samples with styrofoam and saw dust exhibited uniform surface characteristics with pores, thermal stability and no visible surface cracks. It can be concluded that formulations containing 80% kaolin can be used for the production of ceramics with porosities as high as 67% if the right pore formers are used. [ABSTRACT FROM AUTHOR]

In this work, kaolin based ceramics using styrofoam, sawdust, and powdery high density polyethylene as pore formers were experimentally investigated. Prior to batch formulations, the kaolinite used was wet beneficiated. This was followed by mixing starting materials with pore formers, producing green bodies which were then uni-axially compacted into standard sample dimensions and fired at various sintering temperatures of 850°C, 1000°C and 1150°C for 2 hours in a furnace. The physical and mechanical properties of the sintered samples were investigated and the generated data analysed. It was observed that the apparent porosity and water absorption of the samples decreased with increased sintering temperature, while the bulk density, apparent density and cold crushing strength of the samples increased with increased sintering temperature. It was concluded that the samples which were sintered at 850°C with 5% wt pore former of powdery high density polyethylene gave the optimum properties in terms of the porosity and mechanical strength of the samples. [ABSTRACT FROM AUTHOR]

In this study, the crack behaviour of porous kaolin based ceramics was experimentally investigated. The samples (ceramic bodies) were fabricated with the inclusion of pore formers in determined proportions and subjected to heat treatment. Next, the apparent porosity of the samples was measured using the water immersion method. The values confirmed the increased porosity (up to 47%) for the samples with embedded pores. We speculated that the open pores on the surface of the samples which were quite evident, especially with styrofoam as pore formers, may also have penetrated through, hence the enhanced porosity values for the samples. Acoustic emission (AE) activity which reveals the formation of microcracks in the ceramics due to the different thermal expansion coefficients in the cooling stage was recorded for the samples. The first signals of AE counts appeared at 800 °C, where the compressive stresses between the different phases (particles with different coefficients of thermal expansion) led to an appearance of microcracks. By introducing porosity to the samples, the AE signals were less pronounced. This was evident for the samples with sawdust as pore formers, and it was inferred that in this sample, microcracking was suppressed. As a validation protocol for AE measurements, mechanical measurements on the produced samples were conducted through the indentation technique to obtain the fracture toughness of the samples. The results conformed to the observation made during AE measurements. The samples embedded with sawdust as porogens produced the highest fracture toughness of 4.77 MPa.m1/2 by reason of the suppression of microcracking after heat treatment. [ABSTRACT FROM AUTHOR]