Synthesis and fabrication of MgAl2O4 ceramic foam via a simple, low-cost and eco-friendly method

•A new route for preparing mesoporous nanocrystalline MgAl2O4 was proposed.•Low-viscosity MgAl2O4 nanopowder suspensions were prepared using egg white and dispersant.•MgAl2O4 bulk porous ceramic was successfully fabricated using polymer sponge template and the egg albumin-based ceramic suspension.

The MgAl2O4 nanocrystalline powder was synthesized using naturally available egg white and inexpensive metal nitrate salts. During this process, the freshly extracted egg white was mixed with metal nitrate salt and subsequently heated at 350 °C in a pit furnace. The entire dehydration of the aqueous solution thus facilitates the low-density fluffy mass. From TGDTG results, it was observed that maximum decomposition of the precursors occurred below 600 °C. Therefore, the calcination temperature of as-synthesized powder was set at 600 °C. The MgAl2O4 bulk ceramic foam was fabricated by dispersing different loading of MgAl2O4 nanoparticles in the egg white, and then coating on polyurethane sponge prior to drying and sintering at a higher temperature. The ceramic suspensions exhibit a typical shear thinning behavior, and its viscosity was found to be significantly influenced by MgAl2O4 powder content. An optimum loading of 40 wt% MgAl2O4 nanoparticles in the egg white was found to show maximum porosity up to 90%. The obtained ceramic foam has potential applications in catalysis, absorption and sensor.