Reusing Waste Coffee Grounds in the Preparation of Porous Alumina Ceramics

Porous ceramics can be used in various industrial applications, such as thermal insulation, orthopedic implants, high-temperature filtration, lightweight structural components, and catalyst supports, etc., and can be obtained using various methods. In this study, the sacrificial fugitive method was used to prepare a porous alumina ceramic. The appropriate amount of sacrificial fugitive was combined with raw ceramic powder as a pore-forming agent, and was then evaporated or burned out either before or during the sintering process to create the desired pores. Various materials can be used as pore-forming agents; in this work, eco-friendly waste coffee grounds (WCG) were utilized. First, alumina ceramic green bodies were prepared via slip casting of 60 wt. % alumina suspensions with five different amounts of WCG (0 wt. %, 1 wt. %, 5 wt. %, 10 wt. % and 15 wt. %) and the dispersant Dolapix (0.2 wt. %), and using PVA (0.5 wt. %) as a binder for all solutions. The effect of the various amounts of WCG on the alumina ceramic green bodies, and subsequently on the obtained sintered ceramics, was tracked and validated through different analyses. Suspension viscosity was determined through a rotational viscometer. Simultaneous differential thermal and thermogravimetric (DTA/TGA) analyses were used to observe the thermal decomposition of WCG and to determine the sintering regime. After sintering, the density, porosity, and shrinkage of the samples were examined and calculated. In addition, the phase composition and crystallite size of all sintered samples were determined by powder X-ray diffraction (PXRD) analysis, as well as their morphology and composition using Scanning Electron Microscopy (SEM) equipped with energy dispersive X-ray spectroscopy (EDS). The results show that density decreased from 3.743 to 2.172 g/cm(3) and porosity increased from 6.12% to 45.52%, both with the increasing amount of WCG (from 0 wt. % to 15 wt. %).