Industrial Consultancy & Sponsored Research (IC&SR) , IIT Madras

Method for Preparing Porous Mullite Ceramic from Pickering Emulsions

Technology Category/Market

Chemical Engineering: Porous Mullite Ceramic

Industry: Manufacturing, Chemical Engineering

Applications: Advanced materials, medical devices, Equipment to meet stringent.

Market: The global porous ceramic market size was valued at USD 5.98billion in 2020 and is expected to expand at a compound annual growth rate CAGR of 10.4% from 2021 to 2028.

Targeted Industries

Watermarking IP design,

Electronic circuits

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Problem Statement

  • Porous mullite ceramic used in a wide range of applications such as high temperature insulation, filter membrane for highly corrosive and high-pressure environments.
  • However, the functional properties desirable for a given application is highly dependent on the composition and microstructure of the porous network, which in turn depends on the processing technique which described lengthy inefficient processing method and inefficient properties of particles as final ceramic.
  • Hence, there is a need of improved method to overcome above issues.


Present invention describes a method for preparing porous mullite ceramic from Pickering emulsions stabilized by hetero aggregate of oppositely charged fumed oxide particles.

  • The pore size of final ceramic structure is controlled by tuning the emulsion droplet size wherein the droplet size largely depends on the mixing fraction of the particles, aqueous phase pH and the homogenization speed which eventually control the pore size in the final ceramic.
  • The porous ceramic is prepared by drying and sintering of emulsion get stabilized by oppositely charged particles.

The method comprises steps mentioned in below:

  1. Using oppositely charged fumed oxide particles to stabilize oil-in-water Pickering emulsions, wherein the volume ratio of oil phase to aqueous phase fixed at 1:1.
  2. Using Pickering emulsions template that is formulated with fumed oxide nano particles (silica & alumina) to produce green body which is transformed into solid porous material with a controlled porosity and pore size by sintering.
  3. Emulsifying the resulting sample consisting of oil and aqueous phases with a homogenizer (IKA T25 ULTRA TURRAX) at 13000rpm for 3 min.

Key Features/Value Proposition

Technical Perspective:

  1. Current invention facilitates high stability of the particle due to their microstructure.
  2. Extended control over the mouldability of emulsion is ensured by its gel-like behavior.

Industrial Perspective:

  1. The Microstructure of the final ceramic consisting of micron sized pores with nano-porous struts adds to the effective tortuosity, porosity and surface area of the porous mullite material.
  2. The process as claimed in the invention is comparatively less time consuming, and energy consumption reduced.
Questions about this Technology?

Contact for Licensing

Research Lab

 Prof. Basavaraj M. Gurappa

Department of Chemical Engineering

 Prof. Manas Mukherjee

Department of Metallurgical and     Materials Engineering

Intellectual Property

  • IITM IDF Ref. 1839;
  • Patent No. 379956 (Granted)
  • PCT Application No. PCT/IN2020/050457
  • US Application No. US 17/595,893

Technology Readiness Level

TRL- 3/4

Proof of Concept Ready & tested and validated in Laboratory stage.  

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