Preparation of Uniform-Pore Ceramics from Highly Stable Emulsions via the Sol–Gel Method

A facile and cost-effective sol-gel method for the synthesis of uniformly porous alumina (Al₂O₃) was developed using stable CTAB/hexanol/water microemulsions as soft templates. The phase behavior of the ternary system was investigated to identify compositions that form kinetically stable microemulsions, with an optimal ratio of 7.5 wt.% CTAB, 5 wt.% hexanol, and 87.5 wt.% water exhibiting minimal droplet size variation over one week. Gelation was induced by partial neutralization to pH 4.2 with ammonium carbonate, promoting the formation of polynuclear Al species and enabling the uniform entrapment of hexanol droplets. Lyophilization preserved the porous network, and calcination at 500 °C yielded η-Al₂O₃ with a large specific surface area (~225 m²·g^-1) and a narrow mesopore size distribution centered around 100 nm, consistent with the original droplet size. Mercury porosimetry and SEM analyses confirmed a highly porous, low-density material (0.75 g·cm^-3) with an interconnected pore morphology. This scalable synthesis method, supported by the high kinetic stability of the microemulsion, provides sufficient processing time and eliminates the need for post-synthesis purification. It shows strong potential for producing advanced alumina materials for use in energy storage, catalysis, and sensor applications.