Temperature-programmed microwave-assisted synthesis of SBA-15 ordered mesoporous silica.

The currently available microwave technology permits the development and implementation of a temperature-programmed microwave-assisted synthesis (TPMS) of ordered mesoporous silicas (OMSs). Unlike in previously reported syntheses of OMSs, in which only the final hydrothermal treatment was carried out under microwave irradiation, this work takes advantage of the existing capabilities of modern microwave systems to program the temperature and time for the entire synthesis of these materials. To demonstrate the flexibility of the proposed microwave-assisted synthesis, besides programming two consecutive steps involving initial stirring of the gel at a lower temperature and static hydrothermal treatment at a higher temperature, we explored the possibility of temperature programming of the latter step. A major advantage of microwave technology is the feasibility of temperature and time programming, which has been demonstrated by the synthesis of one of the most popular OMSs, SBA-15, over an unprecedented range of temperatures from 40 to 200 degrees C. Since the synthesis of OMSs has not yet been explored and reported at temperatures exceeding 150 degrees C, this work is focused on the SBA-15 samples prepared at higher temperatures (such as 160, 180, and even 200 degrees C). These SBA-15 samples show better thermal stability than those synthesized at commonly used temperatures either under conventional or microwave conditions. Moreover, a partial decomposition of the template during high-temperature microwave-assisted syntheses does not compromise the formation of well-ordered SBA-15 materials. This study shows that the simplicity and capability of temperature and time programming in TPMS allows one not only to tune the adsorption and structural properties of OMSs but also to easily screen a wide range of conditions in order to optimize and scale-up their preparation as well as to significantly reduce the time of synthesis from days to hours.

Synthesis of FDU-1 silica with narrow pore size distribution and tailorable pore entrance size in the presence of sodium chloride.

Ordered silicas with large (9-15 nm), uniform, cagelike mesopores were synthesized under acidic aqueous conditions from tetraethyl orthosilicate in the presence of sodium chloride using poly(ethylene oxide)-poly(butylene oxide)-poly(ethylene oxide) triblock copolymer B50-6600 (EO39BO47EO39, Dow Chemicals) as a supramolecular template. Except for the use of NaCl in our case, the synthesis mixture composition was the same as that originally reported by Zhao et al. for the synthesis of FDU-1 silica, which was later shown to exhibit a cubic close-packed (Fm3m) structure with stacking faults related to the occurrence of hexagonal close-packed stacking sequences. The copolymer-templated silicas were formed at room temperature and in most cases were subjected to the hydrothermal treatment at 373 or 393 K. The calcined materials were characterized using small-angle X-ray scattering (SAXS) and nitrogen and argon adsorption at 77 K. SAXS patterns were generally similar to those reported for FDU-1 silica, indicating the cubic close-packed (Fm3m) structure, but the presence of stacking faults characteristic of a hexagonal close-packed structure cannot be precluded. The addition of the salt was found to significantly narrow the pore size distributions and to improve the uniformity of entrances to the cagelike mesopores, whereas the pore diameter, specific surface area, and pore volume were similar (in most cases slightly lower) to those for FDU-1 silicas obtained in the absence of NaCl. The materials synthesized in the presence of NaCl also appeared to have better resolved SAXS patterns. The feasibility of tailoring the pore cage diameter (from approximately 9.5 to 14.5 nm) and pore entrance diameter (from below 4 to approximately 8 nm) simply by adjusting the hydrothermal treatment temperature and time was demonstrated, indicating that these simple and convenient ways of structural design of cagelike mesopores are operative in the case of syntheses in the presence of inorganic salts.

Synthesis of mesoporous carbons using ordered and disordered mesoporous silica templates and polyacrylonitrile as carbon precursor.

Mesoporous carbons were synthesized from polyacrylonitrile (PAN) using ordered and disordered mesoporous silica templates and were characterized using transmission electron microscopy (TEM), powder X-ray diffraction, nitrogen adsorption, and thermogravimetry. The pores of the silica templates were infiltrated with carbon precursor (PAN) via polymerization of acrylonitrile from initiation sites chemically bonded to the silica surface. This polymerization method is expected to allow for a uniform filling of the template with PAN and to minimize the introduction of nontemplated PAN, thus mitigating the formation of nontemplated carbon. PAN was stabilized by heating to 573 K under air and carbonized under N2 at 1073 K. The resulting carbons exhibited high total pore volumes (1.5-1.8 cm3 g(-1)), with a primary contribution of the mesopore volume and with relatively low microporosity. The carbons synthesized using mesoporous templates with a 2-dimensional hexagonal structure (SBA-15 silica) and a face-centered cubic structure (FDU-1 silica) exhibited narrow pore size distributions (PSDs), whereas the carbon synthesized using disordered silica gel template had broader PSD. TEM showed that the SBA-15-templated carbon was composed of arrays of long, straight, or curved nanorods aligned in 2-D hexagonal arrays. The carbon replica of FDU-1 silica appeared to be composed of ordered arrays of spheres. XRD provided evidence of some degree of ordering of graphene sheets in the carbon frameworks. Elemental analysis showed that the carbons contain an appreciable amount of nitrogen. The use of our novel infiltration method and PAN as a carbon precursor allowed us to obtain ordered mesoporous carbons (OMCs) with (i) very high mesopore volume, (ii) low microporosity, (iii) low secondary mesoporosity, (iv) large pore diameter (8-12 nm), and (v) semi-graphitic framework, which represent a desirable combination of features that has not been realized before for OMCs.