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A general method to carry out the fluorination of metal oxides with poly(tetrafluoroethylene) (PTFE, Teflon) waste by spark plasma sintering (SPS) on a minute scale with Teflon is reported. The potential of this new approach is highlighted by the following results. i) The tantalum oxyfluorides Ta3O7F and TaO2F are obtained from plastic scrap without using toxic or caustic chemicals for fluorination. ii) Short reaction times (minutes rather than days) reduce the process time the energy costs by almost three orders of magnitude. iii) The oxyfluorides Ta3O7F and TaO2F are produced in gram amounts of nanoparticles. Their synthesis can be upscaled to the kg range with industrial sintering equipment. iv) SPS processing changes the catalytic properties: while conventionally prepared Ta3O7F and TaO2F show little catalytic activity, SPS-prepared Ta3O7F and TaO2F exhibit high activity for photocatalytic oxygen evolution, reaching photoconversion efficiencies up to 24.7% and applied bias to photoconversion values of 0.86%. This study shows that the materials properties are dictated by the processing which poses new challenges to understand and predict the underlying factors.
Solid state reactions are slow because the diffusion of atoms or ions through the reactant, intermediate and crystalline product phases is the rate-limiting step. This requires days or even weeks of high temperature treatment, and consumption of large amounts of energy. We employed spark-plasma sintering, an engineering technique that is used for high-speed consolidation of powders with a pulsed Electric current passing through the sample to carry out the fluorination of niobium oxide in minute intervals. The approach saves time and large amounts of waste energy. Moreover, it allows the preparation of fluorinated niobium oxides on a gram scale using poly (tetrafluoroethylene) (®Teflon) scrap and without toxic chemicals.
The synthesis can be upscaled easily to the kg range with appropriate sintering equipment. Finally, NbO2F and Nb3O7F prepared by spark plasma sintering show significant photoelectrocatalytic (PEC) oxygen evolution from water in terms of photocurrent density and incident photon-to-current Efficiency (% IPCE), whereas NbO2F and Nb3O7F prepared by conventional high temperature chemistry show little to no PEC response. Our study is a proof of concept for the quick, clean and energy saving production of valuable photocatalysts from plastic waste.
Thermal decomposition of Zr(C2O4)2·4H2O within an autoclave or in a conventional tube furnace at temperatures below 380 °C resulted in nano- and micron-sized ZrO2, respectively. Reactions under autogenic pressure yielded monodisperse monoclinic (m) and tetragonal (t) ZrO2 nanoparticles with an average diameter of ~8 nm and interconnected t-ZrO2 nanoparticles with diameters of ~4 nm, depending on the synthesis temperature. Samples were characterised by X-ray diffraction (XRD), small angle X-ray scattering (SAXS), scanning electron microscopy (SEM), transmission electron microscopy (TEM) associated with energy dispersive X-ray spectroscopy (EDS), Raman microspectroscopy and photoluminescence spectroscopy (PL). Nanostructured zirconia materials exhibited high specific areas of 276–385 m2 g-1 which make them promising candidates as catalysts and catalyst supports. Co-existence of m- and t-ZrO2 nanoparticles with diameters of 6–9 nm, i.e. above the critical particle size of 6 nm for the formation of t-ZrO2, demonstrated that the particle size is not the only factor for stabilisation of the t-ZrO2 modification at room temperature.