Development of high strength, porous mullite ceramic hollow fiber membrane for treatment of oily wastewater

Ceramic hollow fiber membranes (CHFMs) are known for their excellent characteristics including high surface area, compact design, and good chemical, thermal, and mechanical stabilities. Despite these interesting attributes, CHFMs are also prone to certain limitations, such as brittleness and high cost that hinder them from being commercialized. To mitigate this drawback, we have developed a high strength, porous ceramic hollow fiber membrane, derived from mullite–kaolinite powder, for efficient oil–wastewater separation. The superhydrophilic, low-cost mullite-based (CHFM) was successfully fabricated through combined phase inversion and sintering techniques. Prior to the fabrication, the as-received mullite–kaolinite was characterized using X-ray diffraction (XRD), transmission electron microscopy (TEM), Fourier transform infrared spectroscopy (FTIR), and Brunauer–Emmett–Teller (BET) analyses. Subsequently, operational parameters such as the effect of mullite content, sintering temperature, and air gap were optimized during the fabrication of mullite ceramic hollow fiber membrane. The resulting membranes were systematically characterized and evaluated in terms of morphology, porosity, mechanical strength, water flux, and oil–water separation. Increasing the mullite content, air gap, and sintering temperature enhanced the formation of microvoid structure. It is interesting to note that the mechanical strength of 86 MPa was obtained for the membrane containing 60 wt % of mullite sintered at 1450 °C and an air gap of 5 cm. The membrane induced a stable permeate water flux and oil rejection of mullite CHFM of 182 L/m2∙h and 97.1%, respectively. As compared to kaolin ceramic counterparts, this porous mullite ceramic hollow fiber membrane can be used in various water treatment applications, including for the separation of oily wastewater due to its mechanical strength and water flux.