Rapid thermal process for fabricating α-alumina tight ultrafiltration membrane with narrow pore size distribution

The development of tight ceramic ultrafiltration membranes for water purification facilitates is challenging because of high fabrication costs and low permeate flux. In this study, a low-energy rapid thermal process (RTP) was comprehensively investigated for fabricating of high-precision, permeable α-alumina tight ultrafiltration membranes. Compared to the conventional thermal process (CTP), RTP offers an ultra-fast heating rate and shorter holding time, effectively mitigating grain growth and pore aggregation. Moreover, the decomposition of organic matter is delayed during RTP, providing a lower interfacial energy that enables direct formation of α-alumina at a low temperature of 750 °C. During a secondary subsequent RTP, the residual phase is fully converted to α-alumina by the in-situ seeding effect. By utilizing RTP, we successfully prepared α-alumina ultrafiltration membranes within 30 min by calcination, with an average pore size of approximately 6 nm, a narrow pore distribution coefficient of 1.12, and high permeance of 219 L⁻¹·m⁻²·h⁻¹·bar⁻¹.