Abstract
This work focuses on demonstration of reliable and versatile method for processing cellular mayenite (Ca12Al14O33) -based ceramics with designed porosity, with emphasis on potential catalytic applications. Highly porous (up to 82% of open porosity) monoliths were obtained by emulsification of liquid paraffin in aqueous suspensions of mixed CaCO3 and Al2O3 powders followed by burnout of the organic phase and reactive firing at various temperatures. The results have shown that this method is particularly suitable for processing of mayenite and allows simultaneous retaining of highly open cellular structure with reproducible pore size and a major content of Ca12Al14O33 phase in a wide range of processing conditions. The correlations between firing conditions, minor nominal aluminium excess, porous structure and phase composition were analysed based on Taguchi experimental planning.
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