Reaction-sintered porous mineral-based mullite ceramic membrane supports made from recycled materials

Yingchao Dong*, Jian er Zhou, Bin Lin, Yongqing Wang, Songlin Wang, Lifeng Miao, Ying Lang, Xingqin Liu, Guangyao Meng

*Corresponding author for this work

Research output: Contribution to journalArticlepeer-review

95 Scopus citations


Bulk porous mullite supports for ceramic membranes were prepared directly using a mixture of industrial waste fly ash and bauxite by dry-pressing, followed by sintering between 1200 and 1550 °C. The effects of sintering temperature on the phase composition and shrinkage percent of porous mullite were studied. The XRD results indicate that secondary mullitization reaction took place above 1200 °C, and completed at 1450 °C. During sintering, the mixture samples first shrunk, then expanded abnormally between 1326 and 1477 °C, and finally shrunk again above 1477 °C. This unique volume self-expansion is ascribed to the secondary mullitization reaction between bauxite and fly ash. More especially, the micro-structural variations induced by this self-expansion sintering were verified by SEM, porosity, pore size distribution and nitrogen gas permeation flux. During self-expansion sintering, with increasing temperature, an abnormal increase in both open porosity and pore size is observed, which also results in the increase of nitrogen gas flux. The mineral-based mullite supports with increased open porosity were obtained. Furthermore, the sintered porous mullite membrane supports were characterized in terms of thermal expansion co-efficient and mechanical strength.

Original languageEnglish (US)
Pages (from-to)180-186
Number of pages7
JournalJournal of hazardous materials
Issue number1
StatePublished - Dec 15 2009
Externally publishedYes


  • Fly ash
  • Membrane supports
  • Mullite
  • Self-expansion sintering
  • Waste recycling

ASJC Scopus subject areas

  • Environmental Engineering
  • Environmental Chemistry
  • Waste Management and Disposal
  • Pollution
  • Health, Toxicology and Mutagenesis


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