Mechanochemically enhanced synthesis of isomorphously substituted kaolinites

A mechanochemical method for the rapid, bulk synthesis of kaolinite has been developed. Metal hydroxides and silicic acid are mechanically ground and hydrothermally treated for as little as a day at 250 °C to produce X-ray pure crystalline materials. This approach has been expanded to allow the synthesis of kaolinites with a portion of the aluminum sites isomorphously substituted with other trivalent metals. The synthetic parameters, such as length of mechanical and hydrothermal treatment, were studied. Products were analyzed by powder X-ray diffraction, attenuated total reflectance infrared spectrometry, scanning electron microscopy, and transmission electron microscopy. The samples exhibited strong order along the c axis and less order along the a and b axes. Trivalent transition and rare earth metals were used to replace aluminum in the structure. These metals included Cr, La, Ce, Pr, Nd, Eu, Gd, Ho, and Er. Cerium (III) substituted kaolinite was successfully synthesized utilizing air-free conditions. This approach allows bulk quantities of substituted kaolinites to be prepared in a relatively short amount of time and offers a new route to synthesize pure and substituted kaolinites that may have novel catalytic properties. [Display omitted] ► Hydrothermal treatment of H 2SiO 3 ground with Al(OH) 3 produces kaolin. ► Gram quantities of crystalline kaolin can be rapidly prepared. ► Isomorphous Al substitution can be achieved by including other metal hydroxides. ► Accurate control of Al 3+ substitution level is easily achieved.