My Master thesis its about how to make a filter for industrial application ( water , waste water, metals and exhaust) by polymeric sponge method A.K.A replica method ., any question u can comment below.

1. Fabrication of Ceramic Filter for Water and
Study it’s Properties
By
Sara Hamid Shahatha
Under Super Vision Of
AsstProf. Dr. Mudhafer A.Mohammed

2. The Aim of The Study
 To fabricate ceramic filter for different types of applications like
(hot gas exhaust, water and waste water filtration). It is clear that
many challenges need to be met. These include the relationship
between the microstructure, solid loading, porosity, density and the
mechanical properties behavior.
 In this study, an attempt is made to reveal know how
manufacturing of ceramic filters by polymeric sponge method that
are used in many industries, and used this experience to fabricate
ceramic filters based on porcelain and additives admixtures.

3. Introduction
 Porous ceramics have become increasingly important in industry recently due to
their numerous applications and utilizations involving different materials like
metals, ceramics, polymers, composites, semiconductors and biomaterials.
 Porous ceramics are either reticulate (interconnected voids surrounded by a web
of ceramic) or foam (closed voids within a continuous ceramic matrix).
 Because of the unique combination of their attractive properties, porous
ceramics are considered as candidate materials for several engineering applications.
The production of porous ceramics from polyurethane precursors offers advantages
in terms of simple processing methodology, low processing cost, and easy control
over porosity and other properties of the resultant ceramics.
 Cellular ceramics is considered a class of porous materials, which covers many
types of structures, like foams, honeycombs and interconnected rods, fibers or
hollow spheres. These structures have been used as components in special and
advanced engineering applications, such as filtering liquids and particles in gas
streams, porous burners and biomedical devices.

4. Introduction
 Technique of Porous Ceramics Fabrication
With the growing demand for porous ceramics in
industrial applications, a number of technologies have
developed lately for fabricating these materials :-
 Replication Method
 Starch Consolidation.
 direct Foaming.
 gel-casting of Foam.

5. Introduction
Low High
 Density  Specific strength
 Thermal conductivity  Specific stiffness
 Dielectric Constant  Permeability
 Thermal mass  Thermal shock resistance
 Electrical conductivity  Hardness/wear resistance
 Resistance to chemical action
 Tortuosity of flow paths
Table (1-1) Typical properties of ceramics foam

6. Experimental Part
Raw
Materials
Porcelain
Selecting the
Foam (Polymeric
Sponge)
Vacuum
System
(Saturated the
Sponge)
Microwave
Drying
( 10 – 20 min )
Sintering at
1250 and 1350
ºC
Testing
Preparing of the
Samples
Preparing of the
Loaded Sponge
Preparation
of Slurry
Viscosity, Physical, Mechanical,
Thermal And SEM Tests

7. Fig (1) The procedure of specimen’s preparation: - A. Polymeric sponge, B. vacuum
system, C. Ceramic slurry preparation, D. The loaded templates, E. The specimen after
the sintering in the furnace, and F. The final product of ceramic fillers
Experimental Part

8. Results and Discussion
 Rheological Properties
 The Viscosity and Density of Slurries
Figure (2) Shows the Viscosity of Porcelain and Feldspar at Different Ratios

9. Results and Discussion
Figure (3) Shows the Density of Slurries of Porcelain and Feldspar
at Different Ratios.

10. Results and Discussion
 Physical Properties
 Linear Shrinkage
The drying process in all the ceramic drying process has used the conventional oven but
the conventional oven needs a lot of time up to 48 hours and most of all the dimensions
become unstable and deformed so badly that are like pyramid in shape and also need flip once
in a while and the linear shrinkage is high it has been replaced by microwave oven for these
reasons:-
 The process is faster
 Drying it homegennsily
 The dimensions become stable
 Linear shrinkage is between (0.1- 0.2 mm) and it can be neglected because the microwave
radiation penetrates the samples from top to the bottom in 360°.

11. Results and Discussion
 Porosity
Figure (4) Shows the Porosity
vs. Different (Sintering temp. ,
Feldspar Ratios and Sponge
Densities).

12. Results and Discussion
Foam Density
Figure (5) Shows the Foam
Density vs. Different
(Sintering temp. , Feldspar
Ratios and Sponge Densities).

13. Results and Discussion
 Mechanical Properties
Crushing Strength
Figure (6) Shows the Crushing
Strength vs. Different
(Sintering temp. , Feldspar
Ratios and Sponge Densities).

14. Results and Discussion
Flexural Strength
Figure (7) Shows the Flexural
Strength vs. Different
(Sintering temp. , Feldspar
Ratios and Sponge Densities).

15. Results and Discussion
 Thermal Properties
 Thermal Conductivity
Figure (8) Shows the Thermal
Conductivity vs. Different
(Sintering temp. , Feldspar
Ratios and Sponge Densities).

16. Results and Discussion
 Microstructure Properties
Fig (9) SEM graph of specimen containing (65
wt. % of water, 35 wt. % of Porcelain).
Sintered at (1250) ᵒC. Magnified by different
resolutions.

17. Results and Discussion
Fig (10) SEM graph of specimen containing
(60 wt. % of water, 40 wt. % of Porcelain).
Sintered at (1250) ᵒC. Magnified by different
resolutions.

18. Results and Discussion
Fig (11) SEM graph of specimen containing
(55 wt. % of water, 45 wt. % of Porcelain).
Sintered at (1250) ᵒC. Magnified by different
resolutions

19. Results and Discussion
Fig (12) SEM graph of specimen containing
(50 wt. % of water, 50 wt. % of Porcelain).
Sintered at (1250) ᵒC. Magnified by different
resolutions.

20. Results and Discussion
Fig (13) SEM graph of specimen containing
(45 wt. % of water, 55 wt. % of Porcelain).
Sintered at (1250) ᵒC. Magnified by different
resolutions.

21. Results and Discussion
 The Differences between (Vacuum Preparation and Microwave Drying)
Before and After the Use
 Vacuum Preparation
Fig (14) The differences in preparation of the samples (with the vacuum
system and manually squeezed).

22. Results and Discussion
 Microwave Drying
Fig (15) The specimens in using microwave oven and
conventional oven.

23. Results and Discussion
 Microstructure Images
A B
Fig (4-12) SEM micrograph of ceramic porcelain foam: (A) SEM of
specimen without the vacuum and microwave and (B) SEM with
vacuum and microwave at 300 x magnification to observe the cell
structure.

24. Results and Discussion
 Application
Fig (4-12) The clear water is produced.

25. Conclusion
 The ceramic filter produced in Porcelain solid loading of 50 wt. % has higher mechanical
properties than other variables and the result is light weight foam suitable for filtration.
 The density of the sponge is a major effect factor on the porosity of the final products.
 Vacuum preparation and microwave drying make the samples stronger with minimum linear
shrinkage which could be neglected.
 The micrographs of the samples prepared with vacuum preparation and microwave drying
reveal that the cell thickness increases with the using of these two methods and reveal that the
structure consists of open pore with small percentage of closed pores which decrease with
increasing of solid loading of Porcelain and Feldspar.
 Lower thermal conductivity is obtained when the porosity of the ceramic filter decrease
making the filter suitable for initial thermal insulation.

26. Suggestions for Future Works
Using different materials like alumina and silicon carbide
and studying their effect on the mechanical properties of
the ceramic filter.
Testing the electrical conductivity and studying the ability
of using the filter as electrical insulators.
Using microwave drying and studying its effect on the
mechanical and thermal properties by using different
methods (starch consolidation and direct foaming).

27. Thank you For Listening