Fabrication, characterization and optimization of industrial alpha alumina powders based ceramic membrane supports and its applicative potential for CO2/N2 separation

In this investigation, an economically feasible strategy has been proposed for the fabrication of good quality membrane support by utilizing low-cost industrial-grade alumina powders, coded as A-16SG and CT-1200SG with an average particle size of 0.44 and 1.41 µm, respectively. Herein, the meticulous alteration of the processing parameters and the targeted utilization of industrial grade powders with distinctive particle morphologies have shown promising aspect towards governing the overall sintering and densification behavior, pore morphology and the microstructural facets of the sintered alumina compacts. More precisely, while connecting the structure-property relationship aspect, the broader particle size distribution and the higher quartile ratio of CT-1200SG powders lends to originate relatively higher average pore size and wider pore size distribution in the as-optimized sintered membrane support system in comparison to the narrow particle sized and low quartile ratio comprising A-16SG powder. Additionally, the near surface morphology of the intermediate layers deposited over the two distinctive membrane support systems via implementing differential colloidal chemistry of the respective sols have also been demonstrated for the precise understanding of the role of particle morphology on the progressive perseverance of pore characteristics of the overall asymmetric graded membrane substrate. Finally, the performance evaluation of the alumino-silicate membrane layer assembled on the tailor-made multilayered graded cost-competent alumina support system has been executed which revealed comparable CO2/N2 gas permeance of 46.44GPU and 534.25GPU along with the selectivity of 12.5 and 1.9 for the respective A-16SG and CT-1200SG powders based individual support systems under nearly identical flue gas separation conditions.