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<p>Direct utilization of high iron bauxite mud for fabricating ceramic membrane supports often results in cracking during sintering. To address this issue, this study employed a hydrochloric acid (HCl) leaching pretreatment to remove iron, and the Fe<sub>2</sub>O<sub>3</sub> content of bauxite mud was successfully reducing to below 1%. Under the optimized conditions-15% pore-forming agent, 1.5% binder, and a sintering temperature of 1300&#xa0;°C, the resulting ceramic membrane supports exhibited superior physicochemical properties. The optimized support achieved a porosity of 37.63%, a flexural strength of 20.1&#xa0;MPa, and a mean pore size of 1.21&#xa0;μm, which also delivered high pure water flux of 7075&#xa0;L/h·m<sup>2</sup>·MPa and demonstrated excellent chemical stability with acid and alkali corrosion rates as low as 1.39% and 0.52%, respectively. Furthermore, when tested with simulated industrial wastewater, the ceramic membrane support achieved 99.99% turbidity removal rate. Notably, the leaching by-products were efficiently recovered as Fe(OH)<sub>3</sub> and Al(OH)<sub>3</sub> with recovery efficiencies exceeding 99%.This work presents a sustainable route that combines waste valorization with high-value ceramic membrane supports synthesis.</p>

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Synthesis of high-performance ceramic membrane support from iron-removed bauxite mud

  • 期刊论文

  • 发表日期：

    2026年4月3日

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  • Xiuwu Liu,
  • Xingyu Wang,
  • Dexin Kong,
  • Songling Zhang,
  • Xueqing Chen

摘要

Direct utilization of high iron bauxite mud for fabricating ceramic membrane supports often results in cracking during sintering. To address this issue, this study employed a hydrochloric acid (HCl) leaching pretreatment to remove iron, and the Fe2O3 content of bauxite mud was successfully reducing to below 1%. Under the optimized conditions-15% pore-forming agent, 1.5% binder, and a sintering temperature of 1300 °C, the resulting ceramic membrane supports exhibited superior physicochemical properties. The optimized support achieved a porosity of 37.63%, a flexural strength of 20.1 MPa, and a mean pore size of 1.21 μm, which also delivered high pure water flux of 7075 L/h·m2·MPa and demonstrated excellent chemical stability with acid and alkali corrosion rates as low as 1.39% and 0.52%, respectively. Furthermore, when tested with simulated industrial wastewater, the ceramic membrane support achieved 99.99% turbidity removal rate. Notably, the leaching by-products were efficiently recovered as Fe(OH)3 and Al(OH)3 with recovery efficiencies exceeding 99%.This work presents a sustainable route that combines waste valorization with high-value ceramic membrane supports synthesis.