Hierarchical porous ceramics with 3D reticular architecture and efficient flow-through filtration towards high-temperature particulate matter capture

Porous ceramics with high porosity and extensive interconnected pores have great application potential in fields ranging from dye removal to high-temperature particulate matter (PM) capture. However, constructing these materials to achieve efficient filtration is extremely challenging. Herein, a novel strategy to create hierarchical-structured porous alumina ceramics (PACs) with three-dimensional (3D) reticular architecture is reported based on polyurethane (PU) foaming method. To ensure the efficient flow-through filtration, carbamate-grafted carbon black is used as the pore-forming agent and assembled into the porous PU framework. Submicron and micron-sized pores on the cell walls are observed in hierarchical-structured PACs. This unique structure enables a high PM removal efficiency (94.1%) at an ultralow pressure drop (20 Pa). Our work has demonstrated great application potentials of as-prepared PACs as an efficient high-temperature PM filter and provided new insights to develop highly effective filter.