Process for the preparation of porous mullite

Details Process for the preparation of porous mullite Process for the preparation of porous mullite

C - Chemistry, Metallurgy

04

B

23/186

C04B 38/04 (2006.01) B01J 20/16 (2006.01) B01J 21/16 (2006.01) C04B 35/18 (2006.01)

Patent

CA 1238766

ABSTRACT OF THE DISCLOSURE Clay, preferably kaolin, is calcined through its exotherm, but without substantial mullite formation (e.g., l hour at 1000°C). The calcined clay is leached with an alkaline aqueous solution to remove (i.e., leach) silica. The severity of leaching, i.e., amount of silica removed, determines whether the final product will comprise mullite plus excess Al2O3. If the molar Al2O3/SiO2 ratio is <3/2 the final product will contain mullite plus excess SiO2 and if the Al2O3/SiO2 ratio is >3/2, the final product will contain excess Al2O3. The leached clay is washed, preferably under acid conditions at about pH 3-5, to remove excess alkali ions; and then dried. The washed clay is then calcined at conditions to produce mullite (e.g., 3 hours at 1250°F). Materials made in this manner exhibit high pore volume despite the final high temperature heat treatment.

497530

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