US 12,220,668 B2
High-flux silicon carbide ceramic filter membrane and preparation method thereof
Linfeng Yuan, Nanjing (CN); and Johnny Marcher, Nanjing (CN)
Assigned to Nanjing Hanssen Material Technology Co., Ltd., Nanjing (CN)
Appl. No. 18/280,280
Filed by Nanjing Hanssen Material Technology Co., Ltd., Nanjing (CN)
PCT Filed Apr. 20, 2022, PCT No. PCT/CN2022/087871
§ 371(c)(1), (2) Date Sep. 5, 2023,
PCT Pub. No. WO2022/228227, PCT Pub. Date Nov. 3, 2022.
Claims priority of application No. 202110448901.7 (CN), filed on Apr. 25, 2021; and application No. 202110450376.2 (CN), filed on Apr. 25, 2021.
Prior Publication US 2024/0033690 A1, Feb. 1, 2024
Int. Cl. B01D 67/00 (2006.01); B01D 63/06 (2006.01); B01D 69/02 (2006.01); B01D 71/02 (2006.01); C04B 35/565 (2006.01); C04B 35/626 (2006.01); C04B 35/634 (2006.01); C04B 35/638 (2006.01); C04B 35/64 (2006.01); C04B 38/00 (2006.01); C04B 41/00 (2006.01); C04B 41/45 (2006.01); C04B 41/50 (2006.01); C04B 41/87 (2006.01)
CPC B01D 67/00411 (2022.08) [B01D 63/061 (2013.01); B01D 63/066 (2013.01); B01D 67/0093 (2013.01); B01D 69/02 (2013.01); B01D 71/0215 (2022.08); C04B 35/565 (2013.01); C04B 35/6261 (2013.01); C04B 35/63424 (2013.01); C04B 35/63488 (2013.01); C04B 35/638 (2013.01); C04B 35/64 (2013.01); C04B 38/0006 (2013.01); C04B 38/0054 (2013.01); C04B 38/0096 (2013.01); C04B 41/0072 (2013.01); C04B 41/4539 (2013.01); C04B 41/4578 (2013.01); C04B 41/5059 (2013.01); C04B 41/87 (2013.01); B01D 2323/081 (2022.08); B01D 2325/02834 (2022.08); B01D 2325/20 (2013.01); C04B 2235/3826 (2013.01); C04B 2235/5436 (2013.01); C04B 2235/5445 (2013.01); C04B 2235/5472 (2013.01); C04B 2235/606 (2013.01); C04B 2235/656 (2013.01); C04B 2235/663 (2013.01)] 14 Claims
OG exemplary drawing
 
1. A preparation method of a high-flux silicon carbide ceramic filter membrane, comprising the following steps:
(1) mixing a silicon carbide powder having a first particle size mismatch ratio with a first additive and water, subjecting a resulting mixture to an extrusion molding to obtain a multi-channel tubular green body, and sintering the multi-channel tubular green body at a first temperature for a recrystallization to obtain a support having a microporous structure with a first average pore size on a wall of each of the channels, wherein the silicon carbide powder having the first particle size mismatch ratio comprises a first silicon carbide powder and a second silicon carbide powder, and a median particle size of the first silicon carbide powder is 5 to 30 times a median particle size of the second silicon carbide powder, the first additive comprises a binder, a plasticizer, and a dispersing agent, the binder is methyl hydroxyethyl cellulose or polyvinyl alcohol, the plasticizer is polyethylene glycol, and the dispersing agent is an acrylic polymer, the first silicon carbide powder, the second silicon carbide powder, the binder, the plasticizer, the dispersing agent, and the water are in a mass ratio of (50-75):(10-20):(4-8):(1-3):(1-3):(10-20);
(2) erecting the support, and introducing a coating slurry into channels from a bottom of the support obtained in step (1); when the coating slurry reaches a top of the support, keeping the coating slurry in the channels for a predetermined time; and releasing the coating slurry in the channels to form a channel coating, wherein the coating slurry has a pH of 6 to 10, and particles of the coating slurry and a surface of the support carry like charges;
(3) drying the channel coating obtained in step (2);
(4) under a protection of an inert atmosphere, sintering the channel coating at a second temperature to form a microporous structure with a second average pore size to produce a separation layer; and
(5) subjecting the separation layer obtained in step (4) to an oxidation sintering to remove residual carbon.