Fabrication of porous ceramic from multilayer-coated SiC particles through sol gel followed by in-situ polymerization

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Various processes produce dirty gases at high temperature. Accordingly, ceramic filters are used in industrial processes to protect downstream components and environment, and also to save energy. Silicon carbide is commonly applied as a filter material because of its special properties such as high temperature strength and thermal shock resistance. However, based on engineering reports, a major disadvantage of SiC-based filter is its oxidation to SiO2 in high temperature and humid environments. In addition, available methods to fabricate high temperature filter are not capable to control properly the pore size distribution, porosity, and mechanical stability of filer which are the key factors in filtration efficiency. The objective of this project is to develop a new method for fabricating porous SiC ceramics produced by a combined sol-gel and in-situ polymerization approach. This method can fabricate a porous ceramic which is strongly resistant to oxidation and with the properties of a proper filter. The specific objectives involve controlling the pore size distribution and increasing the mechanical properties as well as porosity of the ceramic porous. The final product will compared with conventional methods currently used in ceramic filter industry. The product can be used in various applications, such as gas solid filtration at high temperature or heat treatment substrates. Preliminary results show that these objectives are very achievable.