A novel transferring strategy to construct outstanding ceramic membranes for high-temperature dust-laden gas filtration

Various industrial processes such as oil refining, metal refining, and chemical industry generate high-temperature dust-laden flue gas. The traditional flue gas treatment technology including wet spray result in significant heat loss and generate secondary pollution, which conflicts with the goals of environmental sustainability and energy conservation. Silicon carbide (SiC) ceramic membranes show great potential for high-temperature gas/solid filtration in industrial processes. However, conventional membrane coating methods often lead to slurry penetration into support channels, resulting in pore blocking. Herein, an innovative membrane-transfer method was proposed to prevent slurry penetration. This method also overcomes the limitation that the membrane particle size must match the pore size of the support. The resulting SiC membranes possessed exceptional higher gas permeance of 212.3 m 3 ·m −2 ·h −1 ·kPa −1 with mean pore size ranging from 1.48 to 2.60 μm. The computational fluid dynamics (CFD) simulation was used to analyze the gas permeation path and confirm the advantage of innovative membrane structure in permeability. Additionally, the SiC membrane showed satisfactory thermal shock resistance after 15 thermal shock cycles (25-800 °C) and 99.99% particle rejection in dust-laden gas (with particle size of 100-300 nm) at 300 °C or 400 °C, showing considerable application potential in industrial dust removal at high temperatures.