Preparation of ceramic foam from
porcelanite by using simple direct foaming
method
Cite as: AIP Conference Proceedings 2123, 020007 (2019); https://doi.org/10.1063/1.5116934
Published Online: 17 July 2019
Enas Muhi Hadi and Huda Jabber Abdul-Hussien
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© 2019 Author(s).
2123, 020007
Preparation of Ceramic Foam from Porcelanite by using
simple direct foaming method
Enas Muhi Hadia), Huda Jabber Abdul-Hussien
Department Applied Sciences, University of Technology, Baghdad, Iraq
a)
Email: enassm.hadi@gmail.com.
Abstract. Ceramics filters should be porous the porous contain large amount of air cells. This work has been carried out
for the purpose of preparing and studying Iraqi ceramic Foam. Simple and non-expensive method (direct foaming
method) invariant friend, invariant friend filter since it makes from natural and raw materials. By using Iraqi raw material
(Porcelanite) and white egg (ovalbumin) as a binder and a foaming agent during the foaming process. Preparing an
Porcelanite particle sizes were less than (≤63) µm, then mixed with white egg (ovalbumin) in ratios between (31.6073.50) %. Porosity, water absorption ratio, permeability, thermal conductivity, and flexural strength were obtained after
sintering the specimens at (1100)˚C. The prepared Porcelanite foam contained a large number of irregular shape
microspores; it has high porosity (55.33-78.90) %, high water absorption ratio (35-59.5) %, high permeability (2.50-4.70)
cm/min and low thermal conductivity (0.42-0.20) W/m.K. with flexural strength range (3-0.55) MPa. The direct foaming
method by using white egg (without water) foam, proved to be an efficient and feasible method for producing highly
porous ceramics with good mechanical properties for Ceramics filter applications. Temperature manufacturing processes.
Keywords: Ceramic Foam, Porcelanite, Ovalbumin, High Porosity, Direct Foaming Method.
INTRODUCTION
Clay is a term for naturally occurring mineral aggregates consisting mainly of the various clay minerals, Clays
and clay minerals are extensively used in a wide variety of industrial applications because of his low cost, inertness
and stability 1,2. Preparing an invariant friend filter since it makes from natural material by using harmless method
without any pollution as a side effects, Ceramic foam is porous brittle materials with closed, fully open, or partially
interconnected porosity Ceramic foams are made from of a wide range of ceramic materials without any pollution
and natural material as additive or foam agent are being considered for the whole range of potential applications.
These include catalysis, thermal insulation, filtration, impact absorbing structures, high specific strength materials
performed for metal-ceramic composites, biomechanical implants, and high-efficiency combustion burners 3,4. There
are three main processing routes for the manufacture of ceramic foam is the sacrificial template 5. The replica
technique 6.
and the direct foaming technique. Among them, the most common one is the direct foaming. It mainly with the
generation of bubbles inside a mixture that contain ceramic powders in order to create a foam which latter needs to
be set in order to maintain its porous morphology, before sintering. To preserve the porous structure, the foam needs
to be consolidated by polymerization or by the use of proteins or ovalbumin as binders which also promote foaming
of the particulate setting of proteins 7. This method is suitable for the fabrication of porous structures with porosities
ranging from ( 45 % to 97) %, cell sizes between 30 µm and 1 mm and porosity generally less open resulting in
lower permeability and higher strength 8. The versatility of this method for foam ceramics synthesis is due to its
simplicity, ease of reproducibility, and low cost 9.
Porcelanite is one of the most important industrial sedimentary rocks. Adsorption capacity of porcelanite is due
to the large surface area within the structures of its components cristobalite and tridymite. The adsorption capacity
for porcelanite made it important for getting rid of the environment from the different pollution. Porcelanite has a
wide range of uses, such as filler, accessory agent, storage medium, carrier, catalyst carrier and catalyst 10. Many
Technologies and Materials for Renewable Energy, Environment and Sustainability
AIP Conf. Proc. 2123, 020007-1–020007-9; https://doi.org/10.1063/1.5116934
Published by AIP Publishing. 978-0-7354-1863-9/$30.00
020007-1
researchers have studied ceramic foams, such as Mortadha who studied porcelanite rocks as adsorption agents in the
chromatography columns for the purposes of the water purification 11. have fabricated macroporous alumina samples
by using the sponge replica and protein direct foaming methods which were compared in terms thereof porosity,
density, compressive strength and microstructure 12. While Liyuan et al., have prepared ceramic foams through
direct-foaming method by using an animal protein as a foaming agent used in their study Kaolin, talc powder and
alumina were the main raw materials 13. In addition, Majid et al., have studied the Iraqi porcelanite to remove
contaminant (Pentachlorophenol) from water via the adsorption mechanism 14. Whereas Bijay et al. have
synthesized porous ceramics based on Al2O3–TiO2/ZrO2–SiO2 from the particle-stabilized wet foam by direct
foaming 15. The goal of the current paper is to investigate direct foam technique in the production of porcelanite
filter, preparing an invariant friend filter since it makes from natural material without any pollution as a side effect
for using, the filter can be easily rescaling.
METHODOLOGY
Materials
Porcelanite was obtained in cooperation with the State Company for Mining Industries and the Ministry of
Industry and Minerals, in Iraq (Western Sahara mines site). Porcelanite is Iraqi crude rock which is available in
economic locally amount for production purposes, Tab 1. composition and ratios of Iraqi porcelanite. The practical
procedure for preparing rocks are crushing and grinding by using a jaw crushing machine then Balls milling. The
resulted powder is sieved then by using a sieve shaker, to yield particle size (≤ 63) µm. Ovalbumin (freshly
extracted from the white egg) was added as a binder to the mixture of Porcelanite and sodium bicarbonate (NaHCO).
Fig. 1 Flow chart for the sample preparation of ceramic foam.
TABLE 1. Composition and ratios of Iraqi Porcelanite and kaolin.
Oxide %
SiO2
Al2O3
CaO
fe2O3
TiO2
K2O
Na2O
MgO
SO3
Cl
P2O5
Porcelanite%
75.39
1.35
3.47
0.87
0.13
0.12
0.90
1.77
0.080
0.73
1.38
Kaolin%
49.38
32.72
1.19
2.07
1.08
0.44
0.22
0.18
0.05
—
—
Raw materials
Crushing
Sieving
Mixing
Casting
Drying
Sintering
Analysis
FIGURE1. Flow chart for the sample preparation of ceramic foam.
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Foam forming
The foam preparation process is going through several steps. The first step involves mixing Porcelanite
powder particle size( ≤63)µm with a constant ratio of sodium bicarbonate. Then preparing white egg (ovalbumin) by
using electrical mixing in order to produce air bubbles. Then adding with different ratios as shown in Tab. 2 without
water. Sodium bicarbonate reacted with white egg (ovalbumin) and generating air bubbles inside the mixture. The
second step includes the casting of the foamed in rectangular and circular silicon rubber molds, which are dried at
room temperature for (24) hr (In this way we have exceeded the long drying hours of the methods with adding
water). After that, the process is followed by the sintering at (1100)ºC for (2) hr with soaking time for (2) hr by
using a programmable furnace (Nabertherm-p310-Germany). FIGURE2 shows a Sintering profile of the foam, Fig.
3 shows the Foam samples.
Foam Code
A
B
C
D
E
TABLE 2. Composition and ratios of foam
Porcelanite(wt)%
NaHCO(wt)%
34.40
73.50
40.23
51.77
51.70
40.30
55.50
36.50
60.40
31.60
W.E. (wt)%
8
8
8
8
8
FIGURE2. Sintering profile of the foam.
FIGURE3. Foam samples.
Testing
The apparent porosity and water absorption are measured by the Archimedes drainage method by ASTM (C373).
While Flexural strength is measured in a 3-Point test by using LARYEE Machine (Computer control electronic
universals testing machine WDW-100), the dimension of the bar- shaped specimens is (6×2×1cm3).
Hydraulic conductivity (Permeability) of the ceramic water filter discs of (3cm) is calculated according to Darcy
law.
Lee̓s disk method is used for determining the thermal conductivity (K) (Philip et al., 2014). This investigation is
carried out by using (40) mm disk radius specimens according to the standard specifications of the instruments using
Lee’s disk type (Griffin & George Ltd - Germany).
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RESULTS AND DISCUSSION
Porosity and water absorption ratios
There is no doubt that porosity is considered one of the most important factors affecting the properties of a
ceramic product, especially high porous and foam products. In the current work, the porosity of the direct forming
method is controlled through the ratios of both white egg and ceramic material (porcelanite), because the foam
mixture is prepared without any amount of water. Fig.4 shows the influences of the ratios of both white egg and
porcelanite on the apparent porosity and water absorption ratio. It has been shown that porosity decreases from
(78.90) % to (55.33) % with increasing porcelanite amount, This is due to the decreases of the white egg and sodium
bicarbonate amount which produce the air bubbles in the foam mixture that is converted to porosity in foam.
Increasing porcelanite amount due to the increase liquid phase at the sintering process and glass phase at product
foam, which filled porous and open channels in the foam. Water absorption ratio depends on the porosity ratio, so
water absorption ratio decreases from (59.50) % to (35.00) % with increasing porcelanite amount, not only porosity
ratio affecting on water absorption ratio, porous size has a clear effect on water absorption ratio, the big porous
produce high water absorption ratio.
80
60
75
55
70
50
65
45
60
40
55
35
A
B
C
D
Water absorption ratio %
Porosity %
Porosity %
Water absorption ratio %
E
Foam code
FIGURE4. Influences of the ratios of both white egg and porcelanite on the apparent porosity and water absorption ratio.
Permeability
Fig.5 shows the influences of the ratios of both white egg and porcelanite on the permeability i.e, permeability
decreases from (4.70) cm/min to (2.50) cm/min with increasing porcelanite amount, Permeability is directly
connected with the ratio of open channels and porous in the foam. So it decreases with porosity ratio decreasing, this
means that porous size has influences on the permeability, the big porous produce high permeability.
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Porosity %
Permeability
5.0
80
Porosity %
4.0
70
3.5
65
3.0
60
Permeability (cm / min)
4.5
75
2.5
55
2.0
A
B
C
D
E
Foam code
FIGURE5.
Influences of the ratios of both white egg and porcelanite on the permeability.
Thermal conductivity
Fig.6 shows the influences of the ratios of both white egg and porcelanite on the thermal conductivity. means
that increasing glass phase, which has high thermal conductivity. The thermal conductivity of thermal insulator
depends on the porosity ratio, porous size, and porous shape. However, it has been recognized (in this study) that the
total porosity tends to decrease with the decreases in porcelanite amount. The big porous and high porosity ratio
produces low thermal conductivity. .
Porosity %
Thermal conductivity
0.45
0.40
Porosity %
75
0.35
70
0.30
65
0.25
60
Thermal conductivity (W/ m.K.)
80
0.20
55
A
B
C
D
E
Foam code
FIGURE6. Influences of the ratios of both white egg and porcelanite on the thermal conductivity.
Flexural strength
Fig.7shows the influences of the ratios of both white egg and porcelanite on the flexural strength. Flexural
strength increases from (0.55) MPa.to (3) MPa. with the increase of porcelanite amount, due to the increased
020007-5
interconnections forces provided by porcelanite and increasing the glass phase which represented a binder phase for
foam. This means that decreasing in porosity. Porosity has a significant role to influence the flexural strength of
porcelanite foam. The flexural strength is inversely proportional to the porosity.
80
3.0
75
2.5
70
2.0
65
1.5
60
1.0
55
0.5
A
B
C
D
Flexural strength (MPa.)
Porosity %
Porosity %
Flexural strength
E
Foam code
FIGURE7. Influences of the ratios of both white egg and porcelanite on the flexural strength.
Pore size analysis
Fig.8 and Fig.9 represented the SEM micrographs of porcelanite foam. These micrographs show that the ceramic
foam has two types of pores; larger pores are having sizes in the range of (50-21.4) µm and smaller pores are having
a size in the range of (15.7-7.1) µm. From SEM micrographs it has observed that the pores have irregular
distribution. The reaction between the materials increased when the white egg and sodium bicarbonate amount
increased, this is due to the increase of larger pores, open channels and open porous ratios in the foam. Closed pores
have an effect on thermal conductivity. Open porous and open channels have an effect on permeability.
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FIGURE8.
SEM micrographs of porcelanite foam surface and microstructure.
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FIGURE 9. SEM micrographs of porcelanite foam (pores size) .
Foam Code
Porosity%
A
B
C
D
E
78.90
69.20
62.50
58.23
55.33
TABLE 3. Properties of foam.
Water
Permeability cm ̸
absorption
min
ratio %
59.50
4.70
57.50
3.50
50.50
2.90
43.00
2.30
35.00
2.50
020007-8
Thermal
conductivity W ̸
m.K.
0.20
0.22
0.25
0.39
0.42
Flexural
strength
MPa
0.55
0.98
1.30
2.5
3
CONCLUSIONS



As this paper has demonstrated, the most important parameters that strongly have an effect
on ceramic foam are porosity and flexural strength, A preparation of ceramic foam by
using ovalbumin as an organic pore former and binder was successfully occurring through
a simple casting process, from Iraqi porcelanite. Sintered ceramic foam showed large pores
(50-21.4) µm and small pores (15.7-7.1) µm, as comparing the foam with other studies that
prepared foam considering small size pores foam.
The best foam ratio is at (60.40)% porcelanite, it has the higher flexural strength (3) MPa.
the foam ratio at (34.40)% porcelanite failure and has the lower flexural strength (0.55)
MPa. The foam at ratios (40.23)%,( 51.70)%,( 55.50)% and (60.40)% porcelanite,
collecting between good flexural strength and high porosity. Ceramic filter prepared by
using Simple and non-expensive method (direct foaming method) invariant friend, invariant
friend filter since it makes from natural and raw materials.
From the results, this porcelanite foam has an important potential for development as
catalysis and water filter. Nevertheless, many other applications may emerge in the near
future.
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