Asymmetric alumina-based ultrathin composite ceramic membranes with interfacial modification of black talc nanosheets

Abstract

In this work, ultrathin planar alumina-based ceramic membranes with asymmetric structure and thickness less than 0.85 mm were successfully prepared by one-step molding phase transformation/sintering method using low-cost black talc (BT) nanosheets for the first time. The microstructure, pore structure, mechanical strength and permeability of novel ceramic membranes were systematically investigated with different BT amount and sintering temperatures. The doping of BT nanosheets effectively modulated the interfacial bonding area and strength between the grains, achieving significant increase in flexural strength through the evolution of the dense layer structure. The asymmetric structural features formed by the phase transformation/sintering process in combination with polymer substrate significantly reduced the thickness of effective separation layer, thus weakening the loss of flux caused by the densification of the film layer due to the interfacial modification process. Moreover, the organic carbon layers between BT layers were oxidized during the sintering process, forming fine pores and increasing the porosity, which showed to be unique characteristic different from other clay mineral materials. The prepared composite membrane had the pure water flux up to 16335 L m−2 h−1/bar at 1350 °C sintering, which achieved stable permeation of ∼5200 L m−2 h−1/bar and high retention over 90% for O/W emulsions.