GOLD-SUPPORTED CARBON CATALYST AND METHOD FOR MANUFACTURING SAME

Abstract

A gold-supported carbon catalyst includes gold fine particles supported on carbon black, wherein the gold fine particles are coordinated by an alkanethiol at a coverage of from 10% to 70%, and wherein the gold fine particles have an average particle diameter of from 1.0 nm to 1.5 nm.

Claims

1. A gold-supported carbon catalyst, comprising: carbon black; and gold fine particles supported on the carbon black, wherein the gold fine particles are coordinated by a dodecanethiol or hexadecanethiol at a coverage of from 10% to 70%, and wherein the gold fine particles have an average particle diameter of from 1.0 nm to 1.5 nm.

2. (canceled)

3. A method of producing the gold-supported carbon catalyst of claim 1, the method comprising: a gold fine particle formation step, which includes: mixing a chloroauric acid aqueous solution and an organic solvent solution containing a phase transfer agent to obtain a liquid mixture, separating an organic solvent solution phase from the liquid mixture, mixing a dodecanethiol or hexadecanethiol into the organic solvent solution phase to obtain a mixed solution, and mixing an aqueous solution containing a reducing agent into the mixed solution to provide gold fine particles coordinated by the dodecanethiol or hexadecanethiol; a gold fine particle treatment step that repeats a series of operations two or more times, including: dispersing the gold fine particles coordinated by the dodecanethiol or hexadecanethiol in hexane, adding a polar organic solvent thereto and mixing the resultant to obtain a mixture, and centrifuging the mixture to obtain the gold fine particles coordinated by the dodecanethiol or hexadecanethiol; and a gold fine particle supporting step, which includes: dispersing the gold fine particles, coordinated by the dodecanethiol or hexadecanethiol and obtained through the gold fine particle treatment step, in hexane to prepare a solution, dispersing carbon black in hexane to prepare another solution, and mixing the prepared solutions to cause the gold fine particles coordinated by the dodecanethiol or hexadecanethiol to be supported on the carbon black.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0011] FIG. 1 is a TEM image of Example 1.

DESCRIPTION OF EMBODIMENTS

[0012] The present invention is directed to a gold-supported carbon catalyst including gold fine particles supported on carbon black, wherein the gold fine particles are coordinated by an alkanethiol at a coverage of from 10% to 70%, and wherein the gold fine particles have an average particle diameter of from 1.0 nm to 1.5 nm. The average particle diameter of the gold fine particles is preferably from 1.2 nm to 1.5 nm.

[0013] The alkanethiol, which is represented by the general formula C.sub.nH.sub.(2n+1)SH, is a water-insoluble thiol including a bonding group containing a sulfur atom that is bonded to a gold surface, a spacer chain of a methylene group, and a head group of a methyl group. Examples thereof include dodecanethiol, hexadecanethiol, and octadecanethiol.

[0014] The gold fine particles are supported on a surface of carbon black in a highly dispersed state. Carbon black has electroconductivity, and its BET specific surface area is from 80 m.sup.2/g to 1,300 m.sup.2/g. In general, a surface functional group, such as a carboxyl group, a lactone group, a phenolic hydroxy group, or a carbonyl group, is present on the surface of carbon black. As the carbon black, for example, Ketjen Black EC300J having a BET specific surface area of about 800 m.sup.2/g or Ketjen Black EC600JD having a BET specific surface area of about 1,270 m.sup.2/g may be used.

[0015] A method of producing the gold-supported carbon catalyst of the present invention includes a gold fine particle formation step, a gold fine particle treatment step, and a gold fine particle supporting step.

[0016] In the gold fine particle formation step, a chloroauric acid aqueous solution is mixed with an organic solvent solution containing a phase transfer agent to obtain a liquid mixture. Then, an organic solvent solution phase is separated from the liquid mixture. Subsequently, an alkanethiol is mixed into the separated organic solvent solution phase to obtain a mixed solution. Next, an aqueous solution containing a reducing agent is mixed into the mixed solution, to thereby provide gold fine particles coordinated by the alkanethiol. Hereinafter, gold fine particles coordinated by an alkanethiol are referred to as alkanethiol-coordinated gold fine particles.

[0017] Specifically, for example, an aqueous solution obtained by dissolving chloroauric acid in pure water and a solution obtained by dissolving tetraoctylammonium bromide in toluene serving as an organic solvent are mixed with each other to subject chloroauric acid to a reaction with tetraoctylammonium bromide serving as a phase transfer agent. Then, an aqueous solution phase is removed from the liquid mixture to obtain toluene solution phase (organic solvent solution phase). Next, dodecanethiol is added to the obtained toluene solution phase (organic solvent solution phase), followed by stirring to mix the resultant to provide a gold complex salt (C.sub.8H.sub.17).sub.4N[Au(C.sub.12H.sub.25S).sub.4] in which a complex coordinated to a gold atom is substituted by a dodecanethiol group (C.sub.12H.sub.25S). In the above-mentioned procedure, the stirring is performed, for example, at 30 C. for 6 hours or more, preferably 12 hours or more.

[0018] Subsequently, the mixture obtained by adding the dodecanethiol to the toluene solution phase (organic solvent solution phase) and mixing them is further mixed with sodium borohydride dissolved in pure water, followed by stirring at from 30 C. to 60 C. for from 1 hour to 4 hours to precipitate gold fine particles coordinated by the dodecanethiol in the toluene solution phase (organic solvent solution phase) through reduction. The toluene solution phase (organic solvent solution phase) is separated, and toluene serving as the organic solvent is removed with an evaporator. Thus, the gold fine particles coordinated by the dodecanethiol are provided as a precipitate. Hereinafter, gold fine particles coordinated by dodecanethiol are referred to as dodecanethiol-coordinated gold fine particles.

[0019] In the gold fine particle treatment step, a series of operations involving dispersing the alkanethiol-coordinated gold fine particles in hexane, adding a polar organic solvent to the dispersion and mixing the resultant to obtain a mixture, and centrifuging the mixture to separate the alkanethiol-coordinated gold fine particles is repeated multiple times.

[0020] For example, methanol or ethanol may be used as the polar organic solvent.

[0021] Specifically, for example, the dodecanethiol-coordinated gold fine particles are dispersed in hexane.

[0022] Next, ethanol serving as the polar organic solvent is added, which is then thoroughly mixed. The mixture is subsequently centrifuged by a centrifugation method. The precipitated gold fine particles, coordinated by the dodecanethiol, are extracted and washed.

[0023] The series of operations is repeated two or more times (multiple times).

[0024] In the above-mentioned step, removal (washing) of unreacted tetraoctylammonium bromide or dodecanethiol adhering to the dodecanethiol-coordinated gold fine particles is performed.

[0025] In the gold fine particle treatment step, the gold fine particles coordinated by the dodecanethiol at a coverage of from 10% to 70% and having an average particle diameter of from 1.0 nm to 1.5 nm are provided.

[0026] In the gold fine particle treatment step, the comparably large-sized gold fine particles each have a small coordination number of dodecanethiol per a unit surface area of the gold fine particles, and the polarity thereof increases relatively. Those fine particles bond to ethanol, which serves as the polar organic solvent, and remain in the liquid without precipitating. Accordingly, it is conceived that comparably large-sized gold fine particles can be removed.

[0027] In the gold fine particle supporting step, a solution is prepared by dispersing the alkanethiol-coordinated gold fine particles, obtained through the gold fine particle treatment step, in hexane. Further, another solution is prepared by dispersing carbon black in hexane. The prepared solutions are then mixed with each other and stirred for 6 hours or more to produce carbon black supporting the alkanethiol-coordinated gold fine particles.

[0028] Specifically, for example, the dodecanethiol-coordinated gold fine particles are irradiated with an ultrasonic wave in hexane to be dispersed. Thus, a gold colloid hexane solution is obtained. Carbon black is irradiated with an ultrasonic wave in a hexane solution to be dispersed. In the above-mentioned step, for example, the dispersion is performed by irradiation with an ultrasonic wave at from 33 kHz to 40 kHz for 1 hour each.

[0029] The two solutions are mixed with each other, followed by stirring at room temperature for, for example, 12 hours, to thereby cause the dodecanethiol-coordinated gold fine particles to be supported on carbon black. The gold fine particles are supported on the carbon black by the stirring. At the time of the mixing of the two solutions, the mixture may be irradiated with an ultrasonic wave for from 10 minutes to 30 minutes.

[0030] Through the above-mentioned steps, the gold-supported carbon catalyst with gold fine particles supported on the carbon black, wherein the gold fine particles are coordinated by an alkanethiol at a coverage of from 10% to 70%, and wherein the gold fine particles have an average particle diameter of from 1.0 nm to 1.5 nm, can be produced. A gold-supported carbon having a gold loading of from 5 wt. % to 70 wt. % can be produced by adjusting a carbon amount with respect to a gold amount.

[0031] A trace amount of water to be absorbed in carbon black at the time of handling is removed when the carbon black is irradiated with an ultrasonic wave in hexane.

[0032] When the coverage of the alkanethiol is less than 10%, adhesive strength of the gold fine particles with carbon black is reduced. Meanwhile, when the coverage of the alkanethiol is more than 70%, a gold surface functioning as a catalyst is not sufficiently obtained. The coverage of the alkanethiol is preferably from 10%- to 70%, more preferably from 15% to 65%.

EXAMPLES

[0033] The present invention is described more specifically below by way of Examples.

Example 1

[0034] A chloroauric acid aqueous solution was prepared by dissolving 21 g of chloroauric acid (HAuCl.sub.4.Math.4H.sub.2O) in 10 g of pure water, and a solution was prepared by dissolving 42.9 g of tetraoctylammonium bromide (phase transfer agent) in 693 g of toluene. The prepared solutions were mixed with each other, followed by stirring at room temperature.

[0035] Next, an aqueous solution phase was removed to obtain a toluene solution phase.

[0036] 31.2 mL of dodecanethiol (a protective agent) was added to the obtained toluene solution phase, and the mixture was stirred for 12 hours.

[0037] After that, a sodium borohydride aqueous solution was prepared by mixing 20 g of sodium borohydride (a reducing agent) and 255 g of ultrapure water. The sodium borohydride aqueous solution was added to the toluene solution phase held at 60 C. at a dropping rate of 10 mL/min. The mixture was stirred for 30 minutes and was then further stirred at 25 C. for 3 hours.

[0038] After that, the aqueous solution phase was removed, and a precipitate was obtained by evaporating toluene with a rotary evaporator.

[0039] Next, a gold fine particle treatment step was performed. This step involved removing excessive amounts of tetraoctylammonium bromide and dodecanethiol from the gold-containing precipitate, as well as removing comparatively large gold fine particles. As the first treatment thereof, the precipitate (=gold colloid) was irradiated with an ultrasonic wave at 40 kHz for 10 minutes to be redispersed in 60 mL of hexane. Then, 500 mL of ethanol was added thereto, and the resultant was mixed. Next, centrifugation was performed at 8,000 rpm and 10 C. for 15 minutes to obtain a precipitate.

[0040] As the second treatment, the precipitate was irradiated with an ultrasonic wave at 40 kHz for 10 minutes to be dispersed again in 24 mL of hexane. 500 mL of ethanol was added thereto, and the resultant was mixed. Next, centrifugation was performed at 8,000 rpm and 10 C. for 15 minutes. After that, a supernatant was removed, and the precipitate was dispersed again in hexane. The hexane solution was evaporated with a rotary evaporator to obtain a precipitate (dodecanethiol-coordinated gold fine particles).

[0041] The obtained dodecanethiol-coordinated gold fine particles were irradiated with an ultrasonic wave at 40 kHz for 30 minutes to be dispersed in 100 mL of hexane. Thus, a gold colloid hexane solution was obtained.

[0042] Next, a solution was prepared by dispersing 90 g of carbon black (EC300J) in 6 L of a hexane solution and irradiating the resultant with an ultrasonic wave at 40 kHz for 1 hour. The resultant solution was then mixed with the gold colloid hexane solution. The mixture was irradiated with an ultrasonic wave at 40 kHz for 30 minutes, followed by stirring at room temperature for 12 hours. Thus, the dodecanethiol-coordinated gold fine particles were supported on carbon black.

[0043] The solution was filtered with a glass filter and was dried at 60 C. to obtain a gold-supported carbon catalyst of Example 1 having a gold loading of 10.8 wt. %.

[0044] The average particle diameter of the gold fine particles of the obtained gold-supported carbon catalyst was 1.4 nm, and a standard deviation thereof was 0.60. A gold particle surface coverage of the coordinated dodecanethiol was 17%.

[0045] (Determination of Average Fine Particle Diameter of Gold)

[0046] The particle diameters of the gold fine particles were measured using a photograph taken by TEM observation (acceleration voltage: 200 kV, magnification: 1,000,000). Thus, an average particle diameter and a standard deviation were calculated.

[0047] (Determination of Gold Particle Surface Coverage of Alkanethiol)

[0048] The number (A) of gold fine particles having an average particle diameter and the number (B) of alkanethiol molecules coordinated to the gold fine particles, per 1 g of the gold-supported carbon catalyst, were each determined from the following formulae. Thus, the number (C=B/A) of molecules of the alkanethiol per gold fine particle was then calculated. A gold particle surface coverage (D) of the alkanethiol was calculated from the formula 3 using the value (C).

A=(gold loading per 1 g of catalyst){(volume of one gold particle having average particle diameter)(volume of one gold atom)197(6.0210.sup.23)}Formula 1

B=X(mass of 1 mol of alkanethiol)6.0210.sup.23Formula 2

[0049] X: mass reduction amount of 1 g of gold-supported carbon catalyst before and after heat treatment at 300 C.

D=(atomic radius of sulfur).sup.2C(surface area of one gold particle having average particle diameter)100Formula 3

Example 2

[0050] A gold-supported carbon catalyst of Example 2 was obtained by the same production method as that of Example 1 except that 31.2 mL of dodecanethiol of Example 1 was changed to 39.4 mL of hexadecanethiol. A gold loading of the obtained gold-supported carbon catalyst was 10.5 wt. %, an average particle diameter of the gold fine particles was 1.4 nm, and a standard deviation thereof was 0.55. A gold particle surface coverage of the coordinated hexadecanethiol was 58%.

Comparative Example 1

[0051] In Comparative Example 1, the gold fine particles were supported on carbon black by the same method as that of Example 1 except that the gold fine particle treatment step was not performed. Thus, a gold-supported carbon catalyst having a gold loading of 7.6 wt. % was obtained.

Comparative Example 2

[0052] In Comparative Example 2, hexadecanethiol was evaporated from the gold-supported carbon catalyst obtained in Example 2 by heat treatment at 200 C. for 1 hour. Thus, a gold-supported carbon catalyst having an average particle diameter of 1.6 nm was obtained.

[0053] The characteristics of the catalysts of Examples 1 and 2 and Comparative Example 1 are shown in Table 1. In addition, a TEM image of Example 1 is shown in FIG. 1. It is found by the TEM image that a catalyst in which the gold fine particles each having a particle diameter of from 1.0 nm to 1.5 nm were uniformly dispersed on carbon black without being aggregated was obtained.

[0054] When the gold particle surface coverage of the alkanethiol of Comparative Example 1 of Table 1 was determined by the formula 3, a value of 100% or more was obtained, but this value was expressed as 100%. This is presumably because the lack of the gold fine particle treatment step caused an excess alkanethiol to entangle with the alkanethiol coordinated to the gold fine particle surface.

TABLE-US-00001 TABLE 1 Average particle Standard Gold diameter deviation particle of gold of gold surface fine fine coverage of Gold particles particle alkanethiol loading (nm) diameter (%) (wt. %) Example 1 1.4 0.60 17 10.8 Example 2 1.4 0.55 58 10.5 Comparative 2.2 0.77 100 7.6 Example 1

[0055] (Adhesive Strength Evaluation)

[0056] The adhesive strength between the gold fine particles and the carbon black support in the gold-supported carbon catalyst was evaluated. The evaluation of the adhesive strength was performed by subjecting the gold-supported carbon catalyst in hexane to ultrasonic irradiation at 40 kHz for 30 minutes. The gold loadings before and after the irradiation were then compared. The gold-supported carbon catalyst was recovered by filtration through a glass filter after the ultrasonic treatment.

[0057] The gold loading of each sample was determined from a mass analysis value of gold and a mass of the gold-supported carbon catalyst.

TABLE-US-00002 TABLE 2 Gold loading (wt. %) Before ultrasonic After ultrasonic Sample wave test wave test Example 1 10.8 10.8 Comparative 7.6 6.7 Example 1

[0058] In Example 1, no change in the gold loading was recognized before and after the ultrasonic wave test, and hence it was found that the adhesive strength between the dodecanethiol-coordinated gold fine particles and the carbon black support was strong. Meanwhile, in Comparative Example 1, the gold loading was reduced after the ultrasonic wave test, and hence it was found that the adhesive strength was insufficient. This is presumably because unreacted tetraoctylammonium bromide or dodecanethiol adhering to the dodecanethiol-coordinated gold fine particles adversely affects the bonding between a functional group of carbon black and the alkanethiol coordinated to the gold fine particles.

[0059] In addition, the gold loading before the ultrasonic wave test in Example 1 where the gold fine particle treatment step was performed was higher as compared to that in Comparative Example 1 where the gold fine particle treatment step was not performed, and hence it is conceived that a supporting speed at which the gold fine particles are supported on carbon increases by performing the gold fine particle treatment step.

[0060] (Aggregation Acceleration Test)

[0061] Example 1 and Comparative Example 2 were evaluated on aggregation of the gold fine particles, which proceeded during use of the gold-supported carbon catalyst, by an acceleration test of heating at 300 C. for 1 hour. The results are shown in Table 3.

[0062] In Comparative Example 2, the aggregation of the gold fine particles proceeded, and an average particle diameter after the acceleration test was largely increased to 5.2 nm. In contrast, in Example 1 where dodecanethiol was coordinated, the average particle diameter was 2.8 nm. That is, it is found that the aggregation of the gold fine particles was suppressed.

TABLE-US-00003 TABLE 3 Change ratio of average particle diameter {(After Average particle diameter of acceleration gold fine particles (nm) test)/ Before After (before acceleration acceleration acceleration Sample test test test)} Example 1 1.4 2.8 2.0 Comparative 1.6 5.2 3.3 Example 1