2.3.3. Drying Conditions and Final Physicochemical Properties of Tannin Gels
After solvent exchange, tannin gels are finally ready to be dried. There are three types of drying procedures that are commonly used in the production of gels, which result in different porous materials with distinct textural properties:
-
Subcritical drying: Gels are dried under atmospheric conditions to form xerogels.
-
Freeze-drying: Gels are dried at freezing conditions to produce cryogels.
-
Supercritical drying: Gels are dried at a critical point of a working fluid to produce aerogels.
The respective dried materials from a gel prepared from tannin and formaldehyde with a resin mass fraction of 6 wt.% and an initial pH of 2 (aerogel, cryogel and xerogel) are presented in
Figure 10 [56]. Visually, it is possible to notice macro differences: (i) Xerogel presents a considerable shrinkage; (ii) Cryogel shows micro cracks due to the formation of ice crystals coming from solvent during the freezing stage; and (iii) Aerogel presents a better preservation of the initial volume and porosity. More details about each of these methods are described below.
Figure 10. Phase diagram of the solvent within the gel structure and the representation of the different drying methods with their respective porous materials, adapted with permission from reference
[56].
Subcritical drying allows the evaporation of solvent at room temperature, or using an oven at temperatures up to 50 °C. It is the simplest and the cheapest method of gels drying. However, the disadvantage of this technique is related to the formation of a liquid meniscus in each pore while solvent evaporates from the surface of the gel. The capillary forces induced by the solvent within the pores generate pressures differences between 100 and 200 MPa
[57], which cause an extreme decrease in the final material porosity.
Lyophilization is a drying process based on freezing the solvent present in the pores, followed by its sublimation
[58]. However, during solvent freezing, dimensional variations of solvent occur, causing tensions in the gel structure. This can cause fissures or even lead to a complete destruction of the initial geometric gel structure, resulting in a powder as a final product
[24]. Therefore, the use of a solvent that has minimum volume variation during freezing is required, coupled with a high vapor pressure to promote sublimation.
Tert-butanol (2-methyl-2-propanol) is generally used to minimize the effects of volume and structural modification of a cryogel due to its low-density (−3.4 × 10
−4 g/cm
3) and low vapor pressure variation (821 Pa)
[58] at the freezing point compared to water, −7.5 × 10
−2 g/cm
3 and 61 Pa, respectively
[59].
The supercritical drying technique is based on increasing both the pressure and temperature of the solvent beyond the critical point to avoid the formation of a vapor-liquid meniscus in the hydrogel pores. Such a technique minimizes gel shrinkage, and consequently the porosity loss due to low capillary forces generated
[54][60]. Organic solvents such as acetone
[40] are used for drying tannin based gels to produce aerogels at a critical temperature and pressure of 250 °C and 14 MPa, respectively. This is known as the "HOT process" where the drying step is carried out at high temperature conditions
[27]. It can also be performed in the presence of CO
2 [22], which is called the "COLD process"
[26][54] at a critical temperature and pressure of 40 °C and 10.4 MPa, respectively. The latter requires the exchange of two solvents due to low solubility of CO
2 in water. First, water is replaced by ethanol, followed by liquid CO
2 exchanging.
Usually, aerogels maintain large part of their geometric and nanometric structures, which is associated to lower volume shrinkage. Thus, the initial porosity is largely preserved, and aerogels regularly present low values of bulk density and high values of specific surface area and pore volumes
[22][40][53].
In order to avoid capillary tension, gels can be synthesized directly in solvents with surface tension lower than water, such as acetone or ethanol. However, as water is always produced during polycondensation reactions
[23], the formation of a vapor-liquid meniscus could not be totally avoided. Thus, surfactants are employed in gels synthesis to reduce the effects of surface tension in xerogels during their drying
[13][61][62] (see more details in
Table 1). Furthermore, surfactants may also be used as a template to produce ordered porous materials based in a self-assembled micellar system
[63]. Xerogels prepared from tannin-formaldehyde with a mass fraction of 25 wt.% and surfactant (Pluronic F-127) (
Figure 11), had bulk densities about (0.28-0.65) g/cm
3 comparable of tannin aerogels
[62]. The numbers 2 to 10 in
Figure 11 refer to initial pH of tannin-formaldehyde-pluronic solutions, and their highest T
gel (~240 min) was found to be at pH 4 and 85 °C
[13].
Figure 11. Tannin-formaldehyde gels prepared with surfactant (
a) top view, and without (
b) bottom view. Reprinted with permission from reference
[62]. Copyright 2011 Elsevier.
Table 1. Organic and carbon gels synthesized at normal conditions.
The use of additives, e.g., surfactants, can decrease the capillary stresses during the drying step. Tannin can indeed be used in a wide range of pH (2–10), differently from lignin and phenol (that only work at alkali pHs) or resorcinol (that only works from mildly acid to alkali pHs). The final texture properties of organic porous gels change with several parameters, such as the pH of the initial solution, the mass fraction of solids, the raw materials, the chemicals employed to modify the initial pH of the solution (alkali and acids), the temperature of gelation, and the drying method used. Thus, there is no unique recipe to control the final properties of gels, since each parameter plays a specific role, as explained before. There is an optimal condition for each system, depending on the desired final property.
A summarized description of organic tannin gels prepared with formaldehyde by different systems, as well as the description of the drying methods used and their physicochemical properties, are reported in Table 1. To produce an organic gel with high specific surface area, it is preferable to choose materials with the highest gelation time (which depends on the pH) and with a mass fraction between intermediate to more diluted (˂20 wt. %). High mesopore volumes are used for tannin gels prepared in the presence of soy, whereas monolithic, unimodal, or bimodal organic gels are readily prepared in the presence of a surfactant such as pluronic.