Separation and Purification Technology 118 (2013) 179-187
Separation and Purification Technology 118 (2013) 179-187
Separation and Purification Technology 118 (2013) 179-187
Laboratoire Sciences des Matriaux et Environnement, Facult des Sciences de Sfax, Route de Soukra Km 4, 3000 Sfax, Tunisia
Institute Europen des Membranes, UMR 5635 (CNRS, ENSCM, UM II), 1919 Route de Mende, 34293 Montpellier Cedex 5, France
a r t i c l e
i n f o
Article history:
Received 27 February 2013
Received in revised form 24 June 2013
Accepted 25 June 2013
Available online 4 July 2013
Keywords:
Carbon/carbon microltration membrane
Phenolic resin
Carbon powder
Carbonization
a b s t r a c t
Tubular carbon microltration membranes have been prepared using mineral coal powder (100 lm average particle size) mixed with phenolic resin solution and organic additives. The porosity of the support
can be sharply controlled by xing the organic additives percentages, the particles size and the homogeneity of the carbon powder. A mesoporous active layer was deposited on the inner face of the carbon support by slip casting using a deocculated slip made of mineral coal powder (1.76 lm) suspended in a
phenolic resin solution. An active layer with an average pore diameter of 0.60 lm is obtained after carbonization under nitrogen atmosphere. The obtained membrane has very interesting characteristics
regarding mechanical and chemical resistances. The application to the treatment of industrial textile
wastewater shows good performances in term of permeate ux and efciency (retention of COD and
salinity of 50% and 30% respectively and almost a total retention of turbidity and color).
2013 Elsevier B.V. All rights reserved.
1. Introduction
Many efforts to achieve economical and efcient membranes
for various uses have resulted in a selection of new materials, an
improvement in membrane preparation techniques and an increase in the number of applications [1,2]. At present, the interest
is derived toward inorganic membranes due to their superior permeabilityselectivity combination and suitable performance for
high temperature or corrosive environment compared to polymeric membranes [3].
Different studies on carbon membranes have shown that they
can successfully compete with polymeric membranes and other
porous inorganic membranes, such as silica- and zeolite-based
membranes, in separation processes of industrial interest. Carbon
material possess a very good chemical and mechanical resistance
whatever the temperature used.
Carbon membrane is generally prepared by carbonization of
various carbonaceous materials [2] such as polyimide [46],
poly-acrylonitrile [7], phenolic resins [810] and polyfurfuryl
alcohol [1113]. Recent studies [14] showed that coal is a good
carbon material that can be used as source of carbon to prepare
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2. Experimental
2.1. Material
2.1.1. Carbon material
Mineral Coal powder was used as the main carbon material
source. To determine the effect of particle size, carbon powders
with different average particle size were prepared. A 200 lm average particles size powder was obtained by crushingsieving of a
raw mineral coal powder. This late powder was ground in a planetary crusher at 300 rpm respectively during 30 min, 2 h and
15 h to obtain three different powders having average particle size
respectively equal to 100 lm, 20 lm and 1.76 lm.
The particle sizing system CILAS 920 was used to determine the
particle size distribution. Thermogravimetric analysis (TGA) and
differential scanning calorimetry (DSC) were performed with
simultaneous DSCTGA 2960 TA instrument to estimate the materials weight loss in a temperature interval varying from 20 to
1000 C with a heating rate of 10 C/min, under nitrogen ow of
1 ml/min.
2.1.2. Thermosetting resin
Phenolic resin marketed by the company Irons Resins S.A, Spain
(Sumitomo Bakelite Co.) was used as carbon precursor, binder and
porosity agent. It is sold in powder form soluble in ethanol containing 7% of hexamine as curing agent.
2.1.3. Organic additives
Organic additives were dry mixed to the carbon powder. Some
of them, as starch powder, were used to enhance the total porosity
of the nal material (since it sublimate during carbonization),
other additives, such as ethylene glycol, amijel and methyl-cellulose are used respectively as lubricants and plasticizers of the paste
to be extruded in tubular form.
Table 1
Materials used to prepare the paste: quantity and function.
Component
Function
Quantity
Powder carbon
Ethylene glycol
Starch (RG 03408, Cerestar)a
Amijel (Cplus 12076,
Cerestar)
Methocel (The Dow Chemical
Company)
Alcoholic solution of phenolic
resin
Mineral charge
Lubricant
Porosity agent
Plasticizer,
binder
Plasticizer
150 g
25.5 g
0%, 4%, 8%, 10%, 12%, 15%
5.75 g
Binder, porosity
agent
120130 ml
5.75 g
a
The different starch quantities are calculated based on the total weight of the
dry components only.
181
Fig. 1. Main steps of the processing route for microltration membrane preparation.
182
Fig. 6. DSCTGA data under nitrogen atmosphere of paste prepared with Novolac
Resin and carbon powder.
The pore structure is formed after all volatile components present in the green body (the additives part and the noncarbonaceous
part of the resin) are sublimated.
3.1.3. Starch
Starch is a complex Glucide composed of molecular chains of DGlucose having a brute formula as: (C6H10O5)n.
The result of DSCTGA analyzes of a sample of starch (Fig. 7)
shows that the mass loss took place in the temperature range of
250550 C and reached the maximum of 61%,37% at 300 C.
It can be clearly seen that when the nal temperature of 750 C
was reached, all starch quantity was sublimated and was then
responsible in part of the material porosity.
As known, powder particle size and organic porous agent percentages (starch in our case), in addition to sintering temperature,
are the most important parameters affecting the structure and the
porosity of porous materials [19]. In the case of carbon membranes
prepared following the process described in this paper, the consolidation of the material is due to the phenolic resin crosslinking. In
addition, resin participate with a constant value to the nal porosity, but the main parameters to control both the pore size and the
porous volume of the nal material are respectively coal particle
size and starch percentage the powder particle size and the presence of starch should also contribute to the structure and porosity
of the membrane.
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Fig. 9. Evolution of porous volume and mechanical resistance with the starch
content.
of the porosity until 12% added starch (limit value) can be attributed to the starch sublimation.
SEM pictures (Fig. 10) shows a drastic change in the nal material texture with the added percentage of starch. 12% starch content show the greatest porosity.
As we can see, the porous texture of the obtained tubular support is not the result of a sintering phenomenon as observed during
the formation of conventional ceramic porous materials [19,24,25].
In fact, the elaborated paste is no more than a composite polymer
in which the resin represents the polymer matrix and the carbon
particles are the mineral charge. During the carbonization step organic additives sublimate and the resin lose weight, thus, only the
carbon skeleton of the resin and the carbon coal particles remained
(Fig. 11).
12% of starch content was found to be the most appropriate to
obtain a material with a good mechanical strength, porosity and
texture.
3.3. Active layer characterization
Fig. 8. Variation of pore size distribution with particle size of carbon powder.
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Fig. 10. SEM images of two samples of carbon supports using 0% starch content and 12% starch content.
Fig. 12. Mercury porosimetry analysis of the microltration membrane for the
different casting time.
The permeability of the support and MF membrane was determined using pure distilled water. Flux values of distilled water at
different operating pressures were measured and were plotted
against transmembrane pressure. Samples were conditioned in
the pure water during the 24 h which precede the ltration, this allows obtaining a fast stabilization of the permeate ux. Permeability was obtained according to the Darcys law (J = DP/l.TMP)
(Fig. 14).
The average values for the elaborated support and MF membrane permeability were respectively 280 L/h m2 bar and 100 L/
h m2 bar.
Contact angle technique is used to estimate the hydrophobicity
character of the material. The measure was repeated 4 times using
a water drop volume varying between 10 and 15 lL. The measures
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Fig. 13. SEM micrographs for carbon microltration membrane obtained with different casting times. Surface texture is shown in the inserts.
1000
cal substances such as dyes, detergents, salts, auxiliaries (e.g. surfactants, emulsiers) and caustic soda are used. Generally, the
wastewater was coming from the dyeing, washing and bleaching
baths (Table 2).
900
800
600
500
400
300
200
100
MF
Support
0
0
0.5
1.5
2.5
3.5
4.5
TMP (Bar)
Fig. 14. Determination of the support and MF membrane permeability.
Table 2
Principle physico-chemical characteristics of textile wastewater.
Parameters
pH
Salinity (g/L)
COD (mg/L)
Turbidity (NTU)
Colorb
Values
8.5
22.8
960
210
52
Integral of the absorbance curve in the whole visible range (400800 nm).
50
45
40
35
J (L/h.m)
J (L/h.m)
700
30
25
20
15
10
5
0
10
20
30
40
50
Time (min)
Fig. 15. Evolution of the permeate ux with time.
60
70
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100%
R (%)
80%
60%
40%
20%
Carbon
Membrane
0%
Salinity
Alumina
Membrane
COD
Turbidity
Color
Fig. 16. Evolution of retention of the different parameters by carbon and alumina
microltration membrane.
carbon precursor using a new process. The porosity and the texture
of the nal material were controlled by adjusting coal particle size
and percentage of organic additives. Tubular support (OD/
ID = 10 mm/8 mm) elaborated by paste extrusion had a porous volume of 38% and a good mechanical and chemical resistances.
The active microltration layer was prepared by slip-casting
process. The casting time was optimized to 6 min which produced
a layer with thickness around 22 lm.
Performances of this membrane toward the treatment of industrial textile wastewater have been studied in term of permeate ux
and efciency. The retention of polluting substances regarding
COD, Turbidity, salinity and color was respectively 57%, 90%, 30%
and 80%.
By comparison with alumina membranes of similar porous
characteristics, carbon microltration membrane showed the best
performances.
Acknowledgements
In order to explain permeate ux decline, the resistance series
model can be used:
RT Rm Rrev Rirrev
RT is the total ltration resistance which represents the distribution of the different resistances. Rm is the inherent hydraulic resistance of clean membrane caused by the membrane itself, it was
given by the determination of pure water permeability. The Rrev
resistance is due to concentration polarization and solids (cake
layer) on the membrane surface, which can be removed by rinsing
with water after the ltration experiment. At the contrary, the Rirrev
resistance is due to pore blocking and absorption of materials onto
the membrane surface and pores, which cannot be removed by a
simple water rinsing but needs a chemical cleaning. After each
run, the membrane was cleaned with pure water and then the permeate water ux was determined, given the Rirrev. The Rrev value
was calculated following:
Rrev RT Rm Rirrev
In our case, the different resistance values are: RT = 3.37 1011 m1, Rirrev = 2 1011 m1 et Rrev = 1.29 1011 m1. The fouling is
rather irreversible (Rrev > Rirrev).
Regarding the permeate quality; a total retention of color and
turbidity was achieved. By an other hand the retention of polluting
substances was higher than 50% except for salinity which was of
only 30%. Indeed, the main mechanism of microltration is usually
sieving but adsorption of organic and mineral pollution towards
membrane surface can also occurred due to ionic and hydrophobic
interaction. So, at high concentration of salt, surface charge effect
can occurred which explains the retention of 30% of salt with initial
concentration of 22 g/L. The difference of charge between the
membrane surface (negative since pH is of 6.9) and the solution
having a pH of 8.5 contributed to this retention. By comparison
with alumina microltration membrane, carbon membrane shows
similar retention of turbidity and COD and higher removal of color
(Fig. 16).
Removal of color is due mainly to the adsorption of dyes onto
the membrane material. Retention of salinity by carbon membrane
is almost twice higher than that obtained by alumina membrane.
Therefore, the carbon microltration membrane seems to be suitable to textile efuent treatment.
4. Conclusion
New carbon/carbon asymmetric microltration membranes
have been prepared based on mineral coal and phenolic resin as
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