Preparation of mesoporous silica nanoparticles with controlled pore size, particle diameter, morphology, and structure by two-step process of chlorosilane residue

Abstract In this study, mesoporous silica nanoparticles (MSNs) were successfully prepared in two steps using chlorosilane residue. First, chlorosilane residue was subjected to alcoholysis with n-propanol to synthesize tetrapropoxysilane (TPOS), followed by the synthesis of MSNs using TPOS as silicon source. Alcoholysis experiment was designed and optimized using orthogonal experimental method. In addition, effects of four factors (i.e., molar ratio of n-propanol to chlorosilane residue; feed rate of n-propanol; reaction temperature; and molar ratio of n-hexane to chlorosilane residue) on the yield of TPOS were investigated. The optimum alcoholysis conditions were determined. Yield of TPOS was 56% under the optimum alcoholysis conditions. Results obtained from single factor analysis of variance revealed that molar ratio of n-propanol to chlorosilane residue was the most significant factor affecting TPOS yield. Next, a series of spherical MSNs with dendritic structure and irregular mesoporous/microporous silica nanoparticles with non-dendritic structure were successfully synthesized via precise regulation of various experimental parameters in emulsion systems. In this regard, the adjustment of n-hexanol/1,3,5-triisopropylbenzene (TIPB) molar ratio or n-octane/n-hexanol/TIPB molar ratio was found to be effective for achieving controllable regulation of morphology (spherical or irregular); structure (dendritic or non-dendritic); pore size (mesoporous (4.6–9.2 nm) or microporous (1.6–1.7 nm)); and particle diameter (60–134 nm) of silica nanoparticles. However, the adjustment of n-octane/TIPB molar ratio marginally affected spherical morphology, dendritic structure, and pore size (4.0–4.6 nm) of synthesized MSNs, with considerable effect on particle diameter (61–151 nm). In addition, as-synthesized MSNs exhibited large specific surface area (708–857 m2/g) and large pore volume (1.5–3.6 cm3/g).