The TG − DSC curves of the reaction between the Mg and SiO2 mixture were displayed in Fig. 1(a). The exothermic peak occurs around 465°C, the slope of the curve at the initial stage of the reaction (465°C − 535°C) is smaller than system temperature reaches 535°C. And the highest temperature was recorded at 575°C. This means that the reaction slowly occurs at the initial stage (465°C − 535°C), the Mg pressure increases with the temperature rise. Thus the reaction is drastic once the Mg vapor pressure is sufficient to diffuse into the SiO2 particles ( at 535°C). The TG curve in Fig. 1(a) indicates that the mass does not change during the reaction. Figure 1(b) shows the real-time temperature profile of the Mg reduction SiO2 obtained by turn-off heating power when the system temperature reaches the exothermic spike, i.e. when the real-time temperature of the system reaches 1270°C. It observes that the temperature slowly rises as time passes, until the 86 minutes, i.e., system temperature at 465°C, the profile suddenly over set temperature and appear exothermic peak. And the profile rapidly increases from 535°C to 1270°C in 20 seconds. It suggests that the MRR releases a large amount of heat, causing the rapid rise of the actual temperature around 535°C. The mass of the reactant (~ 20 g) much larger than the DSC experimental amount (~ 5 mg) is why the highest temperature of the real-time temperature profile is higher than 575°C. The heat conduction and radiation do not effectively dissipate the large quantity of heat released from the MRR in this condition.
To alleviate the local heat accumulation of the MRR process, the heat scavenger, i.e., NaCl, was mixed into the reactants. Table 1 summarizes the adiabatic temperature of the system calculated by HSC 6.0 (Thermochemical analysis software). It clarifies the adiabatic temperature of the MRR process reaches 2325°C, and the added NaCl could reduce the heat accumulation of the MRR exothermic process effectively, shown in systems 2 − 4. Brindley et al. [34] proposed that the formation temperature of Mg2SiO4 is 1100 − 1400°C, described by solid˗state Eq. (5) of Table 2. Thus, adding NaCl into the reactant proportionally (NaCl : SiO2 = 5 : 1 in mole) to control system temperature and avoid byproduct Mg2SiO4. In comparison, the adiabatic temperature of the system is lower when Mg2Si reacts with SiO2, as shown in system 5 of Table 1.
Table 1
The adiabatic temperature at different NaCl addition amounts in the Mg and SiO2 mixture (systems 1 − 4); Mg2Si and SiO2 mixture (system 5)
Systems
|
SiO2 / mol
|
Mg / mol
|
Mg2Si / mol
|
NaCl / mol
|
Adiabatic temperature / °C
|
1
|
1
|
2
|
0
|
0
|
2325
|
2
|
1
|
2
|
0
|
1
|
1810
|
3
|
1
|
2
|
0
|
3
|
1332
|
4
|
1
|
2
|
0
|
5
|
1017
|
5
|
1
|
0
|
1
|
5
|
812
|
After adding NaCl to the reactants, the TG − DSC curves of the reaction are displayed in Fig. 2(a). The exothermic peak occurs around 475°C, and the highest temperature is recorded at 533°C. It indicates that the MRR with NaCl onset temperature is about 475°C and much more violent when the system temperature reaches 533°C. Compared with the exothermic peaks in Fig. 1(a), it can be seen that the exothermic peaks lags and the highest temperature decrease. The melting of NaCl causes the sharp heat absorption peak of the DSC curve around 803°C. The TG curve in Fig. 2(a) also indicates that the mass does not change during the reaction. Figure 2(b) shows the real-time temperature profile of the Mg reduction SiO2 obtained by turn-off heating power when the system temperature reaches the exothermic spike (792°C). As shown in Fig. 2(b), the exothermic peak appears when the system temperature reaches 535°C, with a temperature spike of 792°C. It is clear that adding NaCl can effectively prevent heat accumulation inside the system during the pre-reaction period (475°C − 535°C). What's more, NaCl can destroy the heat accumulation and reduces the temperature (highest temperature from 1270°C decrease to 792°C), but when the MRR is strong, NaCl cannot fully absorb the heat released near 535°C. The NaCl limits the reaction temperature rise over the NaCl melting point. Indeed, the heat released will be used to melt NaCl rather than products.
The temperature profiles in the reactor with different reaction durations (2 h, 4 h, and 8 h) at 650°C are shown in Fig. 3. There are two stages in the MRR actual temperature change process after the system temperature rises to the reaction onset temperature. The first stage shows a significant exothermic peak, which only lasts 30 minutes. Then, the system temperature decreases and remains consistent with the set value at the second stage.
According to the DSC curve in Fig. 1(a) and Fig. 2(a), the magnesiothermic reduction kinetic parameters without and with NaCl in the system were calculated. Assuming β being the ramp rate, starting temperature is T0, and the temperature at the moment t being T = T0 + βt, thus, dT = βdt. The reaction kinetics basic formula of the non-isothermal thermal analysis is based as follows [35]:
Where α is conversion rate; k0 is reaction rate constants; A is the preexponential factor; n is reaction order; E is activation energy; R is the gas constant, 8.314 J·mol− 1·K− 1.
The DSC curve in Fig. 1(a) and Fig. 2(a) integrated to obtain H (heat of reaction accumulation value) at the corresponding temperature point. The modified heat conversion rate (α) can be acquired from H and H0 (total heat effect), as shown in Fig. 4.
The kinetic parameters of the reaction were calculated using the Freeman − Carroll method. The Freeman − Carroll method [36] is widely used without any prior knowledge of the reaction order, the apparent activation energy and order of reaction may be calculated from a single experimental curve. Liu [37] pointed out that the Freeman-Carroll method can only be used to determine the activation energy of a reaction accurately and has a significant error in calculating the reaction order. Therefore, only the apparent activation energy of the reaction was discussed here.
$$\frac{{\Delta \lg ({\text{d}}\alpha /{\text{d}}T)}}{{\Delta \lg (1 - \alpha )}}= - \frac{E}{{19.144}}\frac{{\Delta (1/T)}}{{\Delta \lg (1 - \alpha )}}+n$$
3
This allows obtaining the activation energy E and the reaction order n from the slope and the intercept of a straight line. According to the fitted straight line in Fig. 5, the Freeman − Carroll formula without NaCl in the system can be obtained as:
$$\frac{{\Delta \lg ({\text{d}}\alpha /{\text{d}}T)}}{{\Delta \lg (1 - \alpha )}}= - 10105.3\frac{{\Delta (1/T)}}{{\Delta \lg (1 - \alpha )}}+1.2$$
4
The Freeman − Carroll formula with NaCl in the system can be obtained as:
$$\frac{{\Delta \lg ({\text{d}}\alpha /{\text{d}}T)}}{{\Delta \lg (1 - \alpha )}}= - 9999.7\frac{{\Delta (1/T)}}{{\Delta \lg (1 - \alpha )}}+3.1$$
5
The Freeman − Carroll formula indicates that the apparent activation energy of the reaction was 193.456 kJ·mol− 1 (without NaCl) and 191.434 kJ·mol− 1(with NaCl) in the temperature interval 465 − 700°C, respectively. It means that NaCl does not change the apparent activation energy of the reaction, i.e., NaCl is not involved in the reaction. It is known that when the apparent activation energy is between 42 kJ·mol− 1 and 420 kJ·mol− 1, the limiting link of the reaction is the chemical reaction process[38]. Therefore, the chemical reaction controls the magnesiothermic reduction, and lowering the temperature will reduce the concentration of activated molecules and further decrease the reaction rate. NaCl is lowering the temperature of the system by heat absorption, thereby reducing the rate at which the reaction occurs.
Table 2 showed that the Gibbs free energy change (△G) and enthalpy changes (△H) of different reactions were calculated by HSC 6.0 software. Obviously, all reactions in Table 2 are negative enthalpies reactions. The △G of four equations at 450°C − 650°C, 101325 Pa indicate that the first four reactions could be more easily achieved in thermodynamic conditions than reaction (5), and the reaction proceeds more completely at chemical equilibrium.
Table 2
The △H and △G of different reactions (450°C ~ 650°C, 101325 Pa)
Equations
|
Chemical reaction
|
△H(KJ·mol− 1)
|
△G(KJ·mol− 1)
|
1
|
2Mg(g) + SiO2(s) = Si(s) + 2MgO(S)
|
− (580 ~ 579)
|
− (396 ~ 345)
|
2
|
4Mg(g) + SiO2(s) = Mg2Si(s) + 2MgO(s)
|
− (944 ~ 940)
|
− (606 ~ 522)
|
3
|
2Mg(g) + Si(s) = Mg2Si(s)
|
− (366 ~ 360)
|
− (200 ~ 150)
|
4
|
Mg2Si(s) + SiO2(s) = 2MgO(s) + 2Si(s)
|
− (213 ~ 204)
|
− (192 ~ 190)
|
5
|
SiO2(s) + 2MgO(s) = Mg2SiO4(s)
|
− (62 ~ 64)
|
− (58 ~ 62)
|
Figure 6 presents the XRD patterns of the products obtained by turn-off heating power when the system temperature reaches the exothermic spike (0 h) and different reaction duration under 650°C. As shown in 0 h of Fig. 6(a), the products from MRR contain MgO, Mg2Si, Si, and Mg2SiO4 without indication of Mg, which indicates that the reaction between Mg and SiO2 is rapid and the Mg is consumed entirely. This observation can be confirmed by the DSC curve of the magnesiothermic reduction SiO2 in Fig. 1(a) since there is no pronounced peak of Mg melting heat absorption observed at 648°C. The disappearance of the Mg phase indicates that reactions (1), (2), and (3) of Table 2 have been completed. The large quantities of heat released are why the synthesis of Mg2SiO4 via Eq. (5), which consumes the residual reactant SiO2. These four reactions were completed within 20 minutes (the time used for the system temperature to pass from the reaction start temperature (465°C) to 465°C again) shown in Fig. 1(b). The product composition was almost constant with extended durations. XRD patterns at 650°C for 2 h, 4 h and 8 h proved this point.
However, the typical diffraction peaks of Si, MgO, and Mg2Si can be detected obviously in Fig. 6(b), which means that adding NaCl into the reactant could inhibit the formation of Mg2SiO4 effectively. Thus there is no indication of Mg2SiO4 in the mixture. Figures 7(a)−(d) shows the SEM micrograph and constituent elemental distributions inside the particles (obtained at 0 h and washed by glycol). The particles with a diameter of approximately 25 µm and internal porous morphology were observed. Furthermore, the non-homogeneous elemental distributions of O, Mg, and Si over the particles are shown in the EDS mapping images (Figs. 7(b) − 7(d)). Mg elemental content decreases from the outer layer to the inside, i.e., forming a concentration gradient along the radial direction, which is confirmed by EDS analysis in Fig. 7(e). It could be deduced that Mg2Si and MgO in a 1 : 2 mole ratio roughly generated within the outer layer of the precursor SiO2 particle when forming Si and MgO also at a molar ratio 1 : 2 approximately at grain inside. O elemental of grain outer surface more than the scale value is that the small amount Si has been oxidized. What's more, it also suggests the Mg2Si and MgO are generated via reaction (2) at the outer layer SiO2 aggregate. With Mg gas diffusion to the inner reaction interface, the Mg gas concentration decreases, forming Si and MgO via reaction (1) at grain inside the SiO2 aggregate. The newly generated Si produced near the Mg source will be further converted to form the Mg2Si, reaction (3). These three reactions were completed within 30 minutes (the time used for the system temperature to pass from the reaction start temperature (475°C) to 475°C again) shown in Fig. 2(b).
With the increase of reaction durations, the content of Si increases while Mg2Si decreases, as proved by the increase in the sharp diffraction peaks strength of the phase of Si and decrease of the Mg2Si peak strength, as shown in Fig. 6(b). Only MgO and Si diffraction sharp peaks are present in the reaction product without diffraction peaks of Mg2Si under 8 h. The conversion rate of SiO2 to Si with different reaction durations (Table 3) further confirms these results, showing a 58% conversion rate after 0 h, but the value increased to 62% and 75% after 2 h and 4 h, respectively. Note that the conversion rate of SiO2 is up to 92% when the reaction duration is extended to 8 h at 650°C.
Table 3
The conversion rate of SiO2 to Si at 0 h and with different reaction durations under 650°C (with NaCl)
Reaction durations (h)
|
0
|
2
|
4
|
8
|
Conversion (%)
|
58
|
62
|
75
|
92
|
As shown in Fig. 8, the XRD of three mixtures indicates that synthesized products Si demonstrate different levels of sharp and narrow diffraction peaks without apparent amorphous scattering, indicating a high degree of crystallinity, clearly states that amorphous SiO2 transformed into crystalline Si after the MRR. In addition, it demonstrates that the product Si obtained in 0NaCl − 0 h has sharper peaks compared with that of the Si received in 5NaCl − 0 h and 5NaCl − 8 h, confirming larger crystallite sizes. These results are consistent with the general observation in the literature that added NaCl into reactants could inhibit excessive growth of Si crystalline grains by reducing heat accumulated. Furthermore, compared to the full width at half maximum of the XRD peaks of 5NaCl − 0 h with 5NaCl − 8 h, and we can see that the size of the Si crystal grains grows with increasing reaction duration. This observation is further confirmed by the TEM images of the Si display in Figs. 9(g) and 9(h). We also calculated the fine size of Si crystalline grains by Scherrer analysis based on the XRD patterns of Fig. 8. This yielded an average Si crystallite size of 58.201 nm, 24.835 nm, and 41.034 nm, corresponding to 0NaCl − 0 h, 5NaCl − 0 h, and 5NaCl − 8 h, respectively. In brief, the high temperature would lead to excessive growth of the products Si nanoparticles. Meanwhile, Si crystalline grains would also grow to a specific crystal shape due to the diffusion of Si atoms and the migratory movement of grains with reaction duration increases at a higher reaction temperature (650°C).
Figure 9 displays the SEM and TEM images of reactant SiO2 and the products Si. It shows that the size of the SiO2 particle is 20 µm, as indicated in Fig. 9(a), and each particle is composed of many primary SiO2 nanoparticles (about 25 nm) in Fig. 9(e). As shown in Fig. 9(b), the structure of the obtained product Si changes dramatically compared with that of the precursor SiO2. The smaller nanopores disappear. In contrast, the inter-adhesive macroporous network with a pore diameter (~ 200 nm) and a wall thickness (~ 50 nm) comes into being, which is further confirmed in Fig. 9(f). The Si particles obtained with NaCl are illustrated in Fig. 9(c), which essentially maintain the morphological structure of the precursor SiO2 due to its heat scavenger effect. And the Si nanoparticles with a diameter of about 25 nm show in Fig. 9(g), which is consistent with the result calculated from Scherrer analysis, are loosely interlinked to compose the Si particles around 12.5 µm (Fig. 9(c)). Compared to the precursor SiO2, micron-sized spherical Si particles exhibit volume shrinkage due to the removal of Mg2Si, MgO, and SiO2. Figures 9(d) and (h) show that the structure of the Si also maintained the spherical morphological of the precursor SiO2 after extending the duration to 8 h at 650°C. However, the Si particles diameter increases to around 18 µm, and the primary Si nanoparticles diameter also increases to about 40 nm. It clearly illustrates that crystal grains grow in a specific crystal shape with increasing reaction duration, consistent with the results obtained in Fig. 8.