Materials Transactions, Vol. 55, No. 6 (2014) pp. 892 to 898 © 2014 The Japan Institute of Metals and Materials Preparation and Hydrolysis of Aluminum Based Composites for Hydrogen Production in Pure Water Huihu Wang1,2, J. Lu1, S. J. Dong1,2,+, Y. Chang2,3, Y. G. Fu1 and Ping Luo1,2 1 School of Mechanical Engineering, Hubei University of Technology, Wuhan 430068, China Hubei Provincial Key Laboratory of Green Materials for Light Industry, Hubei University of Technology, Wuhan 430068, China 3 School of Materials Science and Engineering, Hubei University of Technology, Wuhan 430068, China 2 A series of Al based composites were prepared using mechanical milling method in this paper. Effects of additives including CaO, NaCl salt and low melting point metals (Ga, In, and Sn) on the hydrolysis activity of Al based composites were evaluated in pure water. Scanning electron microscopy (SEM) and X-ray diffraction (XRD) techniques were used for the microstructure analysis of as-prepared samples and their hydrolysis products. The results showed that the addition of CaO, NaCl salt and low melting point metals can effectively improve the hydrolysis properties of Al based composites. Especially, Al alloys-CaONaCl composites exhibited a higher hydrogen yields than AlCaO and AlCaO NaCl materials. The SEM images displayed that NaCl salt particles were homogeneously distributed on the surface of Al based composites and inserted into Al matrix, which may damage the surface oxide layer of Al. Furthermore, the size of NaCl salt particles was much smaller in Al alloys-CaONaCl composites than that in AlCaONaCl composites. The XRD patterns identified that the hydrolysis products were mainly composed of AlO(OH) and Al(OH)3. The microstructure-related hydrolysis reaction mechanism of Al based composites was proposed finally. [doi:10.2320/matertrans.M2013425] (Received November 26, 2013; Accepted April 3, 2014; Published May 16, 2014) Keywords: aluminum based composites, mechanical milling, hydrogen 1. Introduction Hydrogen energy has been considered as an alternative of carbon-based fossil fuel for its clean combustion. It can be used to generate electricity through fuel cells or produce heat by directly burning without producing any carbon emissions. Therefore, the wide use of hydrogen is a potential route to reduce the negative impact of the enormous carbon emissions caused by fossil fuels burning.1) Currently, gas,2) coal3) and petroleum4) are the main resources for the industrial hydrogen production. As these resources still belongs to the fossil fuel, the hydrogen production methods based on it could not offer the fundamental solution to the environmental crisis arising by fossil fuel burning. Other energy sources including electricity, solar energy, and biomass energy which involves in the water electrolysis,5,6) water splitting7) and biomass process8) also have been tried to produce hydrogen. Although it seems that these resources are more important than the fossil resources, they are also facing many problems, such as high power consumption and low conversion efficiency. Recently, hydrogen produced by the hydrolysis of active metals, such as Mg, Al, etc. in water has attracted more and more attention for the high hydrogen storage value of metals and the simplicity of reaction system. More important is that the hydrolysis reaction is not involved in carbon emissions,9) thus it is also a green process. Among the active metals, Al is proved to be the best for practical application because of its abundance and low cost. Furthermore, the aluminum oxide hydroxide as the byproducts of hydrolysis reaction is widely used in alumina production, fire inhibition, water treatment, paper making etc. The major obstacle of Al applying for hydrogen production is the thin and dense oxide layer formed on the surface of Al, which may prohibit the hydrolysis of Al. Although alkaline and acid solution can be used to get rid of + Corresponding author, E-mail: [email protected] this oxide layer,10,11) its corrosion characteristic makes the reaction system not suitable for practical applications. Therefore, it is of great importance to develop the method for removing the oxide layer and increasing the activation of Al. Amalgamation is one method frequently used to enhance the activation of Al by using mercury or low melting point metals as alloy elements. For example, mercury can moisten the surface of Al and destroy the surface oxide layer.12,13) However, mercury is very toxic. Low melting point metals including Ga, In, Sn, Zn, Bi etc. can be doped in Al to obtain the active alloys with high hydrolysis activity even at room temperature in different water types.14) The liquid eutectic effect of Al and low melting point metals was ascribed to the enhancement of Al hydrolysis activity. Generally the hydrolysis activity of Al alloys is related to the mass fraction of low melting point metals.1418) The high activity was obtained when the mass fraction of low melting point metal reaches 1030%, which may greatly increase the cost of active Al. Other additives including oxide, salt, and carbon materials were also employed to improve the hydrolysis activity of Al.1927) Babak Alinejad et al.19) reported a novel method to fabricate Al nanoparticles using NaCl salt as additives by milling. The highest average hydrogen generation rate can reach 75 mL/min per 1 g Al in pure water at 70°C. Furthermore, the activated powder can be easily stored for a long time.20) Czech et al.21) investigated the effect of different salt on the corrosion rate of Al powder. Using KCl obtained the higher hydrogen generation rates and hydrogen conversion efficiency in comparison with NaCl. Fan et al.22) discussed the reactivity of AlBi alloys in water by adding different salts including KCl, NaCl, LiCl, MgCl2, AlCl3. The addition of MgCl2 exhibited a better effect than the other salts in improving the reactivity of Al. Wang et al.23) has studied different metal oxides nanocrystals including TiO2, Co3O4, Preparation and Hydrolysis of Aluminum Based Composites for Hydrogen Production in Pure Water Cr2O3, Fe2O3, Mn2O3, NiO, CuO and ZnO as additives to Al powders for hydrogen generation in pure water at room temperature. TiO2 nanocrystals were found to be highly effective for hydrogen generation. Other additives such as Al2O3,24,25) Al(OH)3,26) NaAlO227) were also investigated. Unlike Al alloys activated by low melting point metals, Al based composites prepared by addition of salts or oxides have the merits of low cost. However, its hydrolysis activity may be much lower than Al alloys, especially in pure water at room temperature. In this study, we aimed to find an effective way to produce active Al materials for hydrogen generation with high rate and low cost. Starting from AlCaO system, we further added NaCl salt and low melting point metals Ga, In, and Sn to obtain the Al alloys-CaONaCl composites. The total amount of Ga, In, and Sn was controlled within a very low content. Therefore, both merits of high activity and low cost for alloy elements and salt additives may be inherited in the newly developed Al alloys-CaONaCl composites. 2. Fig. 1 Effect of CaO additive on hydrogen yields for AlCaO composites in water at 60°C. Table 1 Compositions of AlCaO composites and its hydrolysis properties in pure water. Experimental Procedure No. Al powder (200 mush, 99 mass%) was used as starting material. CaO (1250 mush, 98 mass%), NaCl (400 mush, 99.5 mass%), Ga (99.8 mass%), In (200 mush, 99 mass%), and Sn (200 mush, 99 mass%) were employed as additives. To prepare Al based composites, Al powder and additives with total mass 20 g were mixed in an argon-filled glove box at first. Then the mixtures were transferred to the QM-3SP2 planetary ball miller. The ball-to-powder ratio was set as 10 : 1. The milling time and rotation speed were performed for 8 h and 360 r/min, respectively. The as-prepared products were stored in argon-filled specimen bottles in order to avoid oxidation. Hydrolysis reaction was carried out in a 500 mL threenecked bottle. For each test, 1 g of as-prepared products was added into 300 mL pure water in the three-necked bottle. The temperature of water was controlled at 25°C or 60°C in order to evaluate the influence of temperature on the hydrolysis activity of Al based composites. Hydrogen gas was collected through drainage method. The hydrogen conversion efficiency of Al based composites was calculated as follows: E¼ Y 100% ðw%=27Þ 1:5 24:45 ð1Þ Where E is the conversion efficiency of hydrolysis reaction, Y is the actual hydrogen yields (unit-L), w is the mass fraction of Al in composites, 24.45 (unit-L) is the standard volume of 1 mol hydrogen gas at 25°C and 1 atm. The phase structure identification was carried out on a XD2 type X-ray diffractometer with Cu K¡1 radiation (Beijing Purkinje General Co. Ltd.). The step size was set as 0.02°/ step and time per step was 1.2 s/step. The microstructure of Al based composites was recorded using JSM-6390LV scanning electron microscope (SEM) with EDX analysis. 3. Results and Discussions 3.1 Effect of CaO additive Figure 1 shows the hydrogen yields for AlCaO compo- 893 Element composition (mass%) Hydrogen yields (V/mL) Conversion efficiency (%) Al Cao 11 97 3 10 0.78 12 13 95 93 5 7 33 72 2.55 5.69 14 91 9 110 8.89 sites in pure water at 60°C. The detailed mass fraction of CaO additive varies from 3 to 9%, as shown in Table 1. It can be observed that the hydrolysis activity of AlCaO composites in pure water is very low. The total hydrogen yields for Al CaO composites change from 10 to 110 mL with the increase of CaO mass fraction from 3 to 9%, which are far below the theoretical value (1358 mL) for 1 g Al reacting with water completely at 25°C and 1 atm. The corresponding conversion efficiency changes from 0.76 to 8.89%. It is known that CaO is a kind of basic oxide which can react with water to produce Ca(OH)2. For the low solubility of Ca(OH)2 in water, a small amount of hydroxyl ions (OH¹) is formed in pure water which may damage the surface oxide layer of Al and promote the hydrolysis reaction. However, hydrogen generation isn’t observed for AlCaO composites in pure water at 25°C, indicating the electrochemical properties of AlCaO composites are intimately related to the temperature. Although the mass fraction of CaO additives can be raised to enhance the hydrogen yields, the hydrogen storage weight density of AlCaO composites which can be calculated from eq. (2) may decrease rapidly for the reduction of effective Al mass fraction in composites. D¼ mH2 100% mc þ mH2 O ð2Þ Where D is the hydrogen storage weight density, mH2 is the mass of hydrogen generated, mc is the mass of AlCaO composites, and mH2 O is the mass of water consumed in the hydrolysis reaction. Therefore, the mass fraction of CaO additives is controlled below 9%. 894 H. Wang et al. (a) (b) Fig. 2 Effect of NaCl salt additive on hydrogen yields for AlCaONaCl composites in water at 25°C (a) and 60°C (b). Table 2 Compositions of AlCaONaCl composites and its hydrolysis properties in pure water. No. Element composition (mass%) Hydrogen yields (V/mL) Conversion efficiency (%) Al CaO NaCl 25°C 60°C 25°C 60°C 21 91 0 9 0 270 0 21.82 22 88 9 3 9 225 0.75 18.8 23 86 9 5 35 435 2.99 37.20 24 84 9 7 55 515 4.81 45.08 25 82 9 9 68 595 6.10 53.35 3.2 Effect of NaCl salt additive In order to further enhance the activity of Al based composites, NaCl salt was added to AlCaO materials. The mass ratio of different components in AlCaONaCl composites can be seen in Table 2. In contrast to AlCaO materials, the hydrogen yields in pure water at 25°C are observed for AlCaONaCl composites, as shown in Fig. 2(a). The hydrogen conversion efficiency can reach 6.10% for Al9%CaO9%NaCl. Simultaneously, the hydrolysis activity of AlCaONaCl composites is significantly enhanced in pure water at 60°C, as shown in Fig. 2(b). With the increase of NaCl salt mass fraction from 3 to 9%, the total hydrogen yields and conversion efficiency vary from 225 to 595 mL and 18.8 to 53.35%, respectively. For comparison, Al9%NaCl was also produced and its hydrolysis property was examined in pure water at 25 and 60°C, respectively (See Fig. 2 and Table 2). It can be found that Al9%CaONaCl has a higher generation rate than Al 9%NaCl material. When the mass fraction of NaCl salt is higher than 3%, the total hydrogen yields of Al9%CaO NaCl are enhanced obviously. It has been studied that NaCl salt particles can chop Al particles into pieces during milling process. Furthermore, NaCl salt particles are driven into the newly created surface of Al and prohibit the aggregation of Al particles. During hydrolysis, NaCl salt particles are dissolved in water environment. As a result, the fresh Al surfaces will be exposed to water and the hydrolysis proceeding is promoted.19) Combined with the promotion role of CaO additives, the higher hydrolysis activity of AlCaONaCl composites is obtained compared with that of AlCaO and AlNaCl materials. 3.3 Effect of low melting point metal In order to investigate the synergistic roles of low melting point metals with CaO and NaCl, Al alloys-CaONaCl composites were prepared, as shown in Table 3. For comparison, both mass fractions of CaO and NaCl additives were fixed as 9%. It is expected that the hydrolysis activity of Al9%CaONaCl% in pure water can be further improved after the Al part in composites are doped with low melting point metals to form Al alloys component. To study the effect of different alloy elements on the hydrolysis activity of composites, ternary and quaternary Al alloys (AlInSn and AlGaInSn) with different mass fraction of Ga, In, and Sn have been prepared. Figure 3 shows the hydrogen yields of ternary Al alloys9%CaO9%NaCl composites in pure water. In contrast to Al9%CaO9%NaCl composite, the hydrolysis activity of ternary Al alloys-9%CaO9%NaCl composites are enhanced greatly. When the mass ratio of In : Sn is set as 1 : 3, the total hydrogen yields of Al alloys-9%CaO9%NaCl composite in pure water at 25°C reaches 410 mL in 2 h with 38.3% conversion efficiency. When the temperature of pure water increases to 60°C, the conversion efficiency gets to 92.75%, which is near to the complete reaction between Al and water. Furthermore, it can be found that the hydrolysis activity is highly related to the mass ratio of In to Sn in composites. Al alloys-9%CaO9%NaCl composite with mass ratio 1 : 3 has the highest activity in contrast to the other two composites with mass ratio 3 : 1 and 2 : 2. The experimental results also demonstrate that the ternary Al alloys-9%CaO9%NaCl composites possess the higher conversion efficiency than the pure ternary Al alloy (Al1%In3%Sn), as shown in Table 3 and Fig. 3. Figure 4 shows the hydrogen yields of quaternary Al alloys-9%CaO9%NaCl composites. It can be seen that Al based composite with mass ratio 1 : 1 : 2 (Ga : In : Sn) has the highest activity in pure water among all the samples prepared in this experiment. The hydrogen yields and conversion efficiency in pure water at 60°C is 1026 mL and 95.84%, respectively. 3.4 Characterization Figure 5 shows the XRD patterns of ternary Al alloys9%CaO9%NaCl composites. All samples contain the crystalline Al and NaCl phases. It is interesting that the diffraction peak of CaO additive isn’t found in the patterns, Preparation and Hydrolysis of Aluminum Based Composites for Hydrogen Production in Pure Water Table 3 No. 895 Compositions of Al alloys-CaONaCl composites and its hydrolysis properties in pure water. Element composition (mass%) Hydrogen yields (V/mL) Conversion efficiency (%) Al alloys CaO NaCl 25°C 60°C 25°C 60°C 31 100 ðAl : ln : Sn ¼ 96 : 1 : 3Þ 0 0 160 162 11.77 11.91 32 82 ðAl : ln : Sn ¼ 96 : 3 : 1Þ 9 9 140 832 13.08 77.71 9 9 275 965 25.69 90.14 9 9 410 993 38.30 92.75 33 34 82 ðAl : ln : Sn ¼ 96 : 2 : 2Þ 82 ðAl : ln : Sn ¼ 96 : 1 : 3Þ 35 100 ðAl : Ga : ln : Sn ¼ 96 : 1 : 1 : 2Þ 0 0 122 200 8.97 14.71 36 82 ðAl : Ga : ln : Sn ¼ 96 : 1 : 2 : 1Þ 9 9 280 958 28.15 89.48 37 82 ðAl : Ga : ln : Sn ¼ 96 : 1 : 1 : 2Þ 9 9 421 1026 39.32 95.84 (a) (b) Fig. 3 Effect of In : Sn mass ratio on hydrogen yields for ternary Al alloys-9%CaO9%NaCl composites in water at 25°C (a) and 60°C (b). (a) (b) Fig. 4 Effect of Ga : In : Sn mass ratio on hydrogen yields for quaternary Al alloys-9%CaO9%NaCl composites in water at 25°C (a) and 60°C (b). while Ca(OH)2 phase is obtained which may be attributed to the reaction of CaO with water vapor in air. Except these phases, two intermetallic compounds In3Sn and InSn4 are observed. For ternary Al alloys-9%CaO9%NaCl composites, the mass ratio of In : Sn may affect the relative amount of In3Sn and InSn4 in composites. The relative higher diffraction peak intensity of In3Sn phase is observed in Al alloys-9%CaO9%NaCl composites (Al : In : Sn ¼ 96 : 1 : 3), while the higher diffraction peak intensity of InSn4 is found in Al alloys-9%CaO9%NaCl composites (Al : In : Sn ¼ 96 : 3 : 1), as shown in Fig. 5(b). No single In or Sn phase is detected in the patterns. In our previous study, it has been supposed the hydrolysis activity of Al alloys are related to the amount and distribution of intermetallic compounds In3Sn and InSn4.14) The difference on hydrolysis activity of Al alloys-9%CaO9%NaCl composites in this experiment may be ascribed to its phase compositions. The XRD patterns of quaternary Al alloys-9%CaO9%NaCl composites are similar as Fig. 5 (not shown here). Ga phase is not observed in the patterns for its low amount. Similar phenomenon is also observed in Al alloys even with high Ga amount in our previous study and the other literatures.14,16,18) 896 H. Wang et al. (a) (b) Fig. 5 X-ray diffraction patterns of ternary Al alloys-9%CaO9%NaCl composites (a) and the corresponding characterized diffraction peaks of In3Sn and InSn4 (b). (a) (b) (c) (d) Fig. 6 SEM images of Al9%CaO (a), Al9%CaO9%NaCl (b), ternary Al alloys-9%CaO9%NaCl (In : Sn ¼ 1 : 3) (c), and quaternary alloys-9%CaO9%NaCl (Ga : In : Sn ¼ 1 : 1 : 2) composites (d). Figure 6 presents the SEM images of Al9%CaO, Al 9%CaO9%NaCl, ternary Al alloys-9% CaO9% NaCl (Al : In : Sn ¼ 96 : 1 : 3), and quaternary Al alloys-9%CaO 9% NaCl (Al : Ga : In : Sn ¼ 96 : 1 : 1 : 2). It can be seen that many pits and breaks are formed in all samples after mechanical milling process, which may increase more specific exposed surface of Al to water. In contrast to Al 9%CaO (Fig. 6(a)), many regular particles are observed and homogeneously distributed on the surface of the other three samples (Figs. 6(b), 6(c) and 6(d)). For Al9%CaO9%NaCl composite, it seems that the particles are attached on the surface of Al without driving into Al matrix (Fig. 6(b)). However, these particles are inserted inside the matrix of Al alloys-9%CaO9% NaCl composites. In order to examine the element compositions of these particles, EDS spot scanning is used to study the element compositions in designed fields, as shown in Fig. 7 and Table 4 Element compositions in designed fields of Al9%CaO and Al 9%CaO9%NaCl composites. Sample Al9%Cao Al9%CaO9%Nacl Spectrum Element (mass%) Al Na Cl Ca O Spot 1 49.43 0 0 4.72 45.85 Spot 2 49.89 0 0 4.10 46.01 Spot 3 50.20 0 0 3.68 46.12 Spot 1 46.70 4.85 3.79 2.37 43.28 Spot 2 44.11 5.50 4.81 3.17 42.41 Spot 3 46.47 4.00 3.53 2.35 43.66 Table 4. For comparison, Al9%CaO and Al9%CaO 9%NaCl composites are analyzed especially the special particles on the surface of Al9%CaO9%NaCl composite, as shown in spot 1 and 2 in Fig. 7(b). It can be seen that the Preparation and Hydrolysis of Aluminum Based Composites for Hydrogen Production in Pure Water Fig. 7 897 EDS spectra in designed fields of Al9%CaO (a) and Al9%CaO9%NaCl composites (b). Fig. 9 Fig. 8 X-ray diffraction patterns of hydrolysis products for Al based composites. compositions of regular particles mainly consists of element Na and Cl. As there are no such regular particles appearing on the surface of Al9%CaO composite, it is suggested that the regular particles distributed on the surface of the other three composites are NaCl salt. Furthermore, it is shown in Fig. 6 that the size of NaCl salt particles in Al alloys-9%CaO9%NaCl composites is much smaller than that in Al9%CaO9%NaCl composite. According to Rebinder’s effect, the addition of low melting point metals will lead to the embrittlement of Al.15) Therefore, the interaction force between NaCl salt particles and Al powder is enhanced during mechanical milling process. NaCl salt particles are broken into several small pieces and inserted into the breaks and Al matrix. Figure 8 displays the XRD patterns of the hydrolysis products of Al based composites in pure water. As the hydrogen conversion efficiency of Al9%CaO and Al 9%CaO9%NaCl composites is very low, the mainly phase of products is Al. However, the diffraction peak intensity of Al is negligible in the hydrolysis products of Al alloys9%CaO9%NaCl composites. The mainly hydrolysis products are composed of Al(OH)3 and AlO(OH). The diffraction peaks of Al(OH)3 are sharp, while the peaks of AlO(OH) are wide indicating its low crystalline. Proposed reaction mechanism of Al based composites in water. 3.5 Proposed mechanism From the above results, it can be seen that there is a synergistic role of CaO, NaCl salt and low melting point metals additives on improving the hydrolysis activity of Al based composites. By adjusting the mass ratio of different components, the morphology and phase compositions of Al based composites can be effectively tuned, thus the hydrolysis activity and products of Al based composites are quite different. Basically, the aluminum hydrolysis reaction related to hydrogen yields can be expressed as follows: 2Al þ 4H2 O ! 2AlOðOHÞ þ 3H2 ð3Þ or 2Al þ 6H2 O ! 2AlðOHÞ3 þ 3H2 ð4Þ Both two hydrolysis products are found in this experiment. Considering the different components of Al based composites, the microstructure related hydrolysis reaction mechanism is proposed in Fig. 9. As NaCl salt particles have sharp edges and are stiffer than Al powder, they are driven into Al matrix and destroy the surface oxide layer during the high energy ball milling process. These NaCl salt particles are homogeneously distributed on the surface of composites and form the salt gates. In water environment, these salt gates are exposed to water and become the active spots. More salt gates are produced the higher activity of composites are obtained. As Al alloys-9%CaO9%NaCl composites have more tiny and small NaCl salt particles than Al9%CaO9%NaCl 898 H. Wang et al. material, the higher hydrogen yields and conversion efficiency are observed. With the increase of water temperature from 25 to 60°C, the dissolution rate of NaCl salt particles in water is accelerated, which leads to the dissolution of salt gates rapidly and completely. Therefore, the hydrolysis reaction is enhanced. The hydrolysis reaction mechanism of the composites based on salt gates follows the eq. (3). The hydrolysis products are mainly composed of AlO(OH), which has been discussed in literature.19) On the other hand, CaO additives in composites are also dissolved in water environment during hydrolysis reaction as follows: CaO þ H2 O ! Ca2þ þ 2OH ð5Þ The hydroxyl ions acting as the catalyst for the hydrolysis of Al promotes the hydrogen generation. More CaO additives in composites will lead to the formation of higher amount of hydroxyl ions. Therefore, more hydrogen yields are obtained. Under this condition, the hydrolysis reaction mechanism follows the eq. (4). In a conclusion, both two reactions (3) and (4) proceed in the hydrolysis of Al based composites in this experiment, which may be corresponding to two different activation modes. 4. Conclusion The preparation and hydrolysis activity of Al based composites using CaO, NaCl salt and low melting point metals (Ga, In, Sn) as additives were investigated in this work. The Al alloys-CaONaCl composites exhibited the higher hydrolysis yields than AlCaO and AlCaONaCl composites in pure water. It was proposed that the synergistic role of low melting point metals, CaO and NaCl salt are attributed to the improvement of hydrolysis activity. Low melting point metals (Ga, In, Sn) leads to the embrittlement of Al. NaCl salt particles are driven into Al matrix and destroy the surface oxide layer. CaO additives dissolve in water and produce hydroxyl ions. Therefore, all additives promote the hydrolysis reaction of Al and water. 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