Alpha-alumina inorganic membrane support and method of making the same

Abstract

Compositions for making alpha-alumina supports for, for example, inorganic membranes are described. Methods for controlling the alumina and pore former particle sizes and other process variables are described which facilitate desirable porosity, pore distribution and strength characteristics of the resulting alpha-alumina inorganic membrane supports.

1 . A composition comprising;
 from 50 weight % to 90 weight % of α-alumina particles;   from 10 weight % to 30 weight % of organic pore former particles; and   from 1 weight % to 15 weight % of a sintering aid.   
   
   
       2 . The composition according to  claim 1 , wherein the α-alumina has a mean particle size of 15 microns or more. 
   
   
       3 . The composition according to  claim 2 , wherein the α-alumina has a mean particle size of from 15 microns to 50 microns. 
   
   
       4 . The composition according to  claim 1 , further comprising an organic crosslinker. 
   
   
       5 . The composition according to  claim 4 , wherein the organic crosslinker is selected from the group consisting of an organic agent, epichlorohydrin, cyclopolyamine oligomer and ionene. 
   
   
       6 . The composition according to  claim 1 , wherein the sintering aid is selected from the group consisting of boehmite sol, alumina organic compounds, TiO 2 , CuO, MnO 2 , MgO, ZrO 2 , Y 2 O 3 , colloidal alumina, SiO 2 , AlO(OH) slurry, and sodium alumina. 
   
   
       7 . The composition according to  claim 1 , wherein the organic pore former is a starch. 
   
   
       8 . The composition according to  claim 7 , wherein the starch is selected from the group consisting of Canna starch, potato starch, green bean starch, corn starch, rice starch, and Sago starch. 
   
   
       9 . The composition according to  claim 1 , wherein the organic pore former has a mean particle size of from 7 μm to 45 μm. 
   
   
       10 . A method of forming an α-alumina support, the method comprising;
 providing a batch composition comprising 50 weight % to 90 weight % α-alumina particles, 10 weight % to 30 weight % of organic pore former particles and 1 weight % to 15 weight % of a sintering aid;   shaping the batch to form a green body; and   sintering the green body to form the α-alumina support.   
   
   
       11 . The method according to  claim 10 , comprising providing the batch composition by combining the 50 weight % to 90 weight % α-alumina particles, 10 weight % to 30 weight % of the organic pore former particles and 1 weight % to 15 weight % of the sintering aid and mixing the α-alumina particles, the organic pore former particles and the sintering aid to provide a homogeneous mixture. 
   
   
       12 . The method according to  claim 10 , wherein the sintering the green body comprises heating the green body at a temperature of from 1500 degrees Celcius to 2000 degrees Celcius for from 1 hour to 16 hours. 
   
   
       13 . The method according to  claim 10 , wherein the sintering the green body comprises heating the green body at a temperature of from 1600 degrees Celcius to 1775 degrees Celcius for from 8 hours to 16 hours. 
   
   
       14 . The method according to  claim 10 , wherein the organic pore former is a starch. 
   
   
       15 . The method according to  claim 14 , wherein the starch is selected from the group consisting of Canna starch, potato starch, green bean starch, corn starch, rice starch, and Sago starch. 
   
   
       16 . The method according to  claim 10 , wherein the shaping the batch comprises extruding the batch through an extrusion die. 
   
   
       17 . An α-alumina support comprising a mean pore size of from 6 microns to 15 microns and having a pore size distribution (d ps ) of from 0.50 to 1.70 as described by the formula:
     d   ps =( dp   90   −dp   10 )/ dp   50 ;   wherein dp 10  is a pore size wherein 10% of the pore volume has a smaller pore size;   dp 50  is a median pore size wherein 50% of the pore volume has a smaller pore size; and   dp 90  is a pore size wherein 90% of the pore volume has a smaller pore size.   
   
   
       18 . The α-alumina support according to  claim 17 , having a d f  of from 0.20 to 0.60 as described by the formula:
     d   f =( dp   50   −dp   10 )/ dp   50 .   
   
   
       19 . The α-alumina support according to  claim 17 , comprising a first end, a second end, and an inner channel having surfaces defined by porous walls and extending through the support from the first end to the second end. 
   
   
       20 . The α-alumina support according to  claim 19 , wherein the α-alumina support is in the form of a honeycomb monolith.