Preparation of macroporous cordierite monoliths via the sol–gel process accompanied by phase separation

Monolithic cordierite with a cocontinuous macroporous structure has been successfully prepared by the sol–gel process accompanied by phase separation in the presence of poly(acrylamide) (PAAm). Propylene oxide (PO) acts as an acid scavenger to mediate the gelation of MgO–Al2O3–SiO2 ternary system, while PAAm works as a phase-separation inducer as well as a network former. The dried gel and that heat-treated at 800 °C are amorphous, and the sapphirine begins to precipitate at 900 °C, then transforming to orthorhombic β-cordierite at 1100 °C. After heat-treated at and above 1200 °C, the resultant β-cordierite further transforms to stable hexagonal α-cordierite. Heat-treatment changes the macroporous structure of cordierite monoliths such as macropore size and its distribution. The macroporous cordierite monolith after heat-treated at 1200 °C is found to possess a total porosity of 54%, interconnected macropores and dense solid skeletons.