Fabrication of high-performance recrystallized silicon carbide ceramic membrane based on particle packing optimization

Overcoming the challenges associated with achieving high uniformity and connectivity of pore channels in ceramic membranes, we designed silicon carbide ceramic membrane derived from the recrystallization process based on the Dinger-Funk equation of the closest-packing model with various grain grading. Furthermore, the effects of particle size distribution on the resulting microstructure and pore architecture of the ceramic membrane was also explored. The findings corroborated the critical importance of raw material particle size distribution in controlling pore size distribution and morphology. After sintering at 1900°C, the silicon carbide ceramic membrane, benefiting from ideal particle packing, exhibited a remarkably uniform pore structure. Notably, the most probable pore size constituted over 70 %, while achieving an open porosity of 51.3 % even without the addition of pore-forming agents. The silicon carbide ceramic membrane also demonstrated exceptional hydrophilicity (water contact angle:∼0°), impressive water permeation (1210 L m⁻² h⁻¹·bar⁻¹), coupled with efficient turbidity removal (∼100 %) in carbon black wastewater treatment applications. Additionally, membrane regeneration proved effective using a dilute NaOH solution backwash, achieving a flux recovery efficiency of 98 %. This strategy had directive significance for designing high-performing silicon carbide ceramic membranes.