CA2310317A1 - A method for the sub-critical drying of lyogels to produce aerogels - Google Patents

A method for the sub-critical drying of lyogels to produce aerogels Download PDF

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Publication number
CA2310317A1
CA2310317A1 CA002310317A CA2310317A CA2310317A1 CA 2310317 A1 CA2310317 A1 CA 2310317A1 CA 002310317 A CA002310317 A CA 002310317A CA 2310317 A CA2310317 A CA 2310317A CA 2310317 A1 CA2310317 A1 CA 2310317A1
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Canada
Prior art keywords
drying
fixed bed
gel
drying gas
sub
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Abandoned
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CA002310317A
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French (fr)
Inventor
Johannes Hartel
Rainald Forbert
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Cabot Corp
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Individual
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Publication of CA2310317A1 publication Critical patent/CA2310317A1/en
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    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F26DRYING
    • F26BDRYING SOLID MATERIALS OR OBJECTS BY REMOVING LIQUID THEREFROM
    • F26B3/00Drying solid materials or objects by processes involving the application of heat
    • F26B3/02Drying solid materials or objects by processes involving the application of heat by convection, i.e. heat being conveyed from a heat source to the materials or objects to be dried by a gas or vapour, e.g. air
    • F26B3/06Drying solid materials or objects by processes involving the application of heat by convection, i.e. heat being conveyed from a heat source to the materials or objects to be dried by a gas or vapour, e.g. air the gas or vapour flowing through the materials or objects to be dried
    • CCHEMISTRY; METALLURGY
    • C01INORGANIC CHEMISTRY
    • C01BNON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B33/00Silicon; Compounds thereof
    • C01B33/113Silicon oxides; Hydrates thereof
    • C01B33/12Silica; Hydrates thereof, e.g. lepidoic silicic acid
    • C01B33/14Colloidal silica, e.g. dispersions, gels, sols
    • C01B33/157After-treatment of gels
    • C01B33/158Purification; Drying; Dehydrating
    • C01B33/1585Dehydration into aerogels

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  • Chemical & Material Sciences (AREA)
  • Dispersion Chemistry (AREA)
  • Engineering & Computer Science (AREA)
  • Organic Chemistry (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Microbiology (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Inorganic Chemistry (AREA)
  • Silicon Compounds (AREA)
  • Drying Of Solid Materials (AREA)
  • Colloid Chemistry (AREA)

Abstract

The present invention refers to a method for the sub-critical drying of lyogels to produce aerogels. The method for the sub-critical drying of lyogels to produce aerogels provides for the lyogel particles to be disposed as a fixed bed and for a drying gas to be passed through them.

Description

Description A method for the sub-critical drying of lyogels to produce aerogels The invention relates to a method for the sub-critical drying of iyogels to produce aerogds.
Lyogels are gels which cornain a liquid, the dispersing agent. In the partica~lar instance where the gel fluid is water, they are also referred to as hydrogels. In the present Application, the term'lyogel' also includes hydrogels. Aerogels in the wider sense, i.e. in the sense of "gel with air as the dispersant", a suitable gel is produced by drying. The term "aerogels" in this sense includes aerogels in the narrower sense, xerogels and cryogels.
In this respect, a dried gel is referred to as an aerogel in the narrower sense if the fluid of the gei is eliminated at temperatures above the critical temperature and starting from pressiu es which are above the critical pressure. On the other hand, if the fluid of the gel is reanoved sub-~tically, for e~ple with the formation of a fluid-vapour interface, then the resulting gel is also frequently refenred to as a xerogel.
VVhe~ the use of the te~cm serogels in the present Application is concerned, there are gels which are sub-critically dried.
Aemgds have a very low density and high porosity for solid substances.
Therefore, and on account of the minimal pore size, aerogels, particularly those with pomsities of over 60% arai densities below 0.6 g/cu.cm, display an exrranely low thermal conductivity and are therefore used as heat insulating materials such as are described for instance in EP-A
0 171 722.
For industrial applications, aerogels are predominamly used as Vie. For the application, it is in this respect essential for the aerogel granulate to be used to consist of particles of a suitable form, preferably spherical form, and size distribution.
By virtue of their low density, however, aerogels also exhibit low mechanical stability, particularly in respect of sheer loadings and against abrasion.
By reason of the capillary forces which occur in sub-critical drying and the shrinkage involved, not all l5ro~gels are suitable for sub-aitical drying to produce an aemgel. During dryings the gel shrinks considerably if the meniscus of the fluid migrates imo the interior of the gel, in order, with effect from a certain point in the drying process, to spring back more or less completely into its staring form again. Consequently, depending upon the qualities of the inner gel , a certain minimum stability of the gel network is esse'nbal, modification of the inner gel surface often being required in order to prevent a reaction by adjacent pore walls in the sbtunk condition and a collapse of the gel which this would entail.
Corresponding processes in which the inner s<uface of an Si02 lyogel is organically modified and the resulting gel is sub-critically dried to produce an aerogel, are disclosed for example in US-A 5 565 142, DE-A-43 42 548 and in the unpublished German Patent Application 19648798.
Gels which are unsuitable for sub-critical drying collapse under ~b-critical drying, with a loss of the porous structure and therefore they no longer display the favourable properties of axrogels.
According to the gel, modification, granular form and size and drying conditions, so gel particles can, during drying, be destroyed on a macroscopic scale, i.e.
while r~simng the nanoporovs structure. It is true that the aerogel retains its properties but on aocoimt of the now smaller granular size an irregular or undefined grain shape, it can no longer be used so satisfactorily.
Drying methods which at first sight appear obvious for such drying problems are not readily suited to major industrial production of aerogel granulate of a definite form.
By reason of tix low density of the aerogels, a fluid bed drying system has been found to be unsuited to major industrial production. In order not to carry the aerogel particles out of the layer, it would be necessary to work below the fluidising point; the necessary gas flow velocities would then be so low that there would be no guarantee of heat being supplied and vapour dispersed in an acceptable time for drying. Were greater gas flow velocities to be used, then the aerogel would not be complctely dried since it will be conveyed out of the dryer. Furthermore, in the fluidised phase, gel particles collide with one another so that there is considerable abrasion and grain fracture.
Contact drying to be not sufficiently effective since due to the high heat insulating capacity of the aerogels, a transfer of heat into layers more remote from the contact surface does not take place quickly enough so that only mi~mal layer' thicknesses and therefore, in view of the quantities need, excessively great surface areas would be needed.
In aooordance with DE-A-43 16 540, aerogels are dried by dielectric processes.
Due to tire necessary electtical anti the neladvely high investment for an appropriate drying apparatus, however, these methods are not sufficiently economical.
The'<efore, the obit of the present ion was to provide a method for the sub-critical drying of lyogels which are suitable for sub-critical drying to produce aerogels and which mitnrnises the destruction of aaogel particles and the abrasian of aerogel particles during drying and which can be used on a large industrial scale.
Surprisingly, the problem is resolved by a method for the sub-critical drying of lyogels to produce aerogels and which is characterised in that the lyogel particles are disposed as a static bed and have a dry gas flowing through them.
Carried out in this way, the drying does not lead to grain fracture or abrasion since the particles are stationary in their bulls. Surprisingly, the drying can be carried out in relatively short times and in layer heights which are considerable for fixed bed drying.
In pdr~iple, any l5rog~ls which can be dried sub-critically are suitable for the method, i.e.
their gel structure must be sufficiently stable to withstand collapse of the framework by the action of capillary forces and are if necessary suitably surface modified in order for example to prevent a reaction between pore walls in the shnrnken condition.
Where the lyogels are concerned, these may according to the type of gel structure be organic or inorganic lyogels. For example, they can be produced on a basis of metal oxides which are Suitable for the Sol-gel technical (G. J. Brinker; G. W.
Scherer, Sol-Gel Science 1990, ct>apters 2 and 3), such as for example Si- or Al-compounds or on the basis of organic substances which are suitable for the sol-gel technique such as for example melamine formaldehyde condensates (US-A-5 086 085) or resorcin formaldehyde condo (US-A-4 873 218) or even on the basis of mixtures of the above-mentioned materials. Preferably, they are Si02 gels and particularly preferably organically surface modified Si02 gels such as are described for example in the unpublished German Patent Application No. 19648798.
Wliexe the gel fluid is von~ed, this may in principle be pure substances or mixtures, the gel fluid preferably comaining more than 50'/o by weight of organic solvents, preferably acetone or hexamethyl disiloxane. Naturally, the gel fluid may also contain small quantities of otl~r substances such as for example hydrochloric acid or residues of water.
The lyogel particles can in principle be of any desired form and size but preferably substantially spl~rica! particles with diameters between 100 um and 5 cm and particularly preferred are those with diameters between 0.5 mm and 5 mm. It is also possible to dry mixtures of particles of different shape and/or different size.

WO 99/32218 Ptr1'/EP98108244 In order to avoid already dried and therefore lightweight aerogel particles being blown away, it would among other things be necessary for the velocity of the dry gas flow to be low so that no dried aerogel particles are carried away. However, this results in low gas flows and therefore a very listed input. For drying aerogels, a rapid energy input is advamageous. For using relatively high drying gas flow velocities, the bulk must therefore, at those places where the gas flow emerges from the fixed bed, be limited by at least one arrangement which is permeable to the drying gas but not to the particles.
Surprisingly, the fixed bed is preferably and in per se known ma~mer, traversed by the drying gas flow passing through it downwards, so that the arrangement which is permeable to the drying gas but not to the particles is constituted by the carrier of the fixed bed. The drying apparatus which is then to be used is consequecitly not only simpler and less expensive but grain frachue is also reduced, since the upper layers which press down onto those underh are the first to be dried. The dried and mechanically sensitive aerogess then lie on the heavier and less dried and also mechanically loadable gel particles and are not heavily loaded mechanically.
For a continuous operation, the fixed bed may also be moved with the carrier, e.g. on a suitable belt. Preferably, the gas flow then passes through the fixed bed crosswise to the direction of movement.
The thickness of the fixed bed in the direction of flow of the drying gas stream can be surprisingly great. Preferably, it is between 20 cm and 100 cm and particularly preferably between 20 and 60 cm.
Any gas suitable for drying can be used as the drying gas; if the gel fluid comains large fiactions of organic solvents, then possibly an inert gas such as nitrogen should be used.
The input gas flow can already contain solvent gas which the process allows, in other words a ciradatory pattern of gas flow, whereby, as usual, solvent gas is constantly b eliminated from the circuit, for example by condensation. To accelerate the drying as a whole, it may be advarrtageous first to dry the gel in a circulatory fashion but to use fresh drying gas for drying the last residues of gel fluid.
The method aoco~ling to the invention can be carried out by apparatus known to the man skilled in the art, e.g. fiaoed bed driers, suitable containers with screen bottoms or suitable drying belts, etc., which may possibly be modified in a manner evident to a man of the art.
Preferably, the method for drying modified Si02 aerogds such as disclosed for example in DE-A-43 42 548 or in the unpublished German Patent Application 196 487 98 will be used.
In this case, if the gel fluid contains more than 50% by weight hexamethyl disiloxane or acetone, then the temperature of the drying gas is preferably between 100°C and 200°C
and with particxrlar preference between 140°C and 180°C.
In the case of the said surface modified Si02 aerogels, the incident flow velocities are pn~rably in the range between 1 and 40 curls and particularly preferably between 5 and 30 curls.
A)thaugh the method is particularly suitable for producing aerogels with densities below 300 glcu.cm, it is also possible to use it for drying xerogels of greater density.
The method aooording to the invention will be described hereinafter with reference to an example of embodiment but without however being limited thereby.
Example:
A modified Si02 lyogel which has been produced in accordance with examples 1 to 4 in the unpublished German Patent Application 1964877798 and which has a sharp grain see diction around 1 mm diameter is dried in a fixed bed with a height of 50 cm with a stream of nitrogen flowing through the fixed bed from the top downwards at an inad~t flow vdoc~y of 20 cxnls and with a gas inlet temperature of 160°C. L~itially, the gel is dried for 2'f~ hours in a circulatory manner, the drying Bas leaving the fixed bed saturated with moisture and after thorough condensation with a charge of lOglkg inert gas, it is again introduced into the fixed bed. Afterwards, drying is continued for half an-hour with fresh drying Bas. The dried aerogel displays virtually no grain fracture and hardly awy abrasion.

Claims (12)

claims
1. A method for the sub-critical drying of lyogels to produce aerogels, characterised in that the lyogel particles are disposed as a fixed bed and have drying as passed through them.
2. A method according to claim 1, characterised in that, at those locations at which the gas flow from the faced bed, the fixed bed is bounded by at least one arrangement which is permeable to the drying gas but not to the particles.
3. A method according to claim 2, characterised in that the fixed bed lies on the said means and has the flow passing through it from the top downwards.
4. A method according to at least one of claims 1 to 3, characterised in that the lyogel is an organically modified gel tire framework of which contains SiO2.
5. A method according to claim 4, characterised in that the gel fluid predominantly contains hexamethyl disiloxane.
6. A method according to claim 4, characterised in that the gel fluid predominantly contains acetone.
7. A method according to at least one of claims 4 to 6, characterised in that the temperature of the drying gas at the inlet is between 100°C and 200°C.
8. A method according to 6 or 7, characterised in that the incident flow velocity is between 1 cm/s and 40 cm/s.
9. A method according to at least one of the preceding claims, characterised in that the thickness of the fixed bed is between 20 cm and 100 cm in the direction of flow of the drying gas stream.
10. A method according to at least one of the preceding claims, characterised in that the drying gas follows a circulatory system.
11. A method according to at least one of the preceding claims, characterised in that in a first phase of drying the drying gas is circulated while in a second phase fresh drying gas is used.
12. A method according to at least one of the preceding claims, characterised in that the fixed bed is moved together with the means bounding it, the stream of drying gas being passed through the fixed bed crosswise to the direction of movement.
CA002310317A 1997-12-19 1998-12-16 A method for the sub-critical drying of lyogels to produce aerogels Abandoned CA2310317A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
DE19756633A DE19756633A1 (en) 1997-12-19 1997-12-19 Lyogels and aerogels subcritically dried in a packed bed with minimal particle breakdown
DE19756633.2 1997-12-19
PCT/EP1998/008244 WO1999032218A1 (en) 1997-12-19 1998-12-16 A method for the sub-critical drying of lyogels to produce aerogels

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CA2310317A1 true CA2310317A1 (en) 1999-07-01

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US (1) US6378229B1 (en)
EP (1) EP1042059B1 (en)
JP (1) JP4450989B2 (en)
KR (1) KR100523465B1 (en)
CN (1) CN1111445C (en)
AU (1) AU2273799A (en)
BR (1) BR9813736A (en)
CA (1) CA2310317A1 (en)
DE (2) DE19756633A1 (en)
ES (1) ES2191989T3 (en)
WO (1) WO1999032218A1 (en)

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JP2001526107A (en) 2001-12-18
DE19756633A1 (en) 1999-06-24
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US6378229B1 (en) 2002-04-30
BR9813736A (en) 2000-10-10
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EP1042059B1 (en) 2003-03-05
KR20010032475A (en) 2001-04-25
AU2273799A (en) 1999-07-12
CN1111445C (en) 2003-06-18
CN1282270A (en) 2001-01-31
ES2191989T3 (en) 2003-09-16

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