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Applied Clay Science 131 (2016) 107–112

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Applied Clay Science

journal homepage: www.elsevier.com/locate/clay

Research paper

Reflections on the material science of clay minerals


Robert A. Schoonheydt
Department of Microbial and Molecular Systems, Katholieke Universiteit Leuven, Kasteelpark Arenberg 23, 3001 Leuven, Belgium

a r t i c l e i n f o a b s t r a c t

Article history: Possible new applications of clay minerals are explored continuously. Three such areas are clay-polymer
Received 17 August 2015 nanocomposites, clay mineral films and clay mineral catalysts. Advances in these areas must come from
Received in revised form 7 December 2015 the increase of fundamental knowledge of the clay minerals, especially the expanding clay minerals or
Accepted 7 December 2015
smectites. Examples of fundamental research areas are: the mechanical properties of single clay layers
Available online 19 December 2015
and the change of these mechanical properties with the number of layers in a clay mineral particle; control
Keywords:
of the organization of clay mineral layers and of molecules in the interlayer space for the production of func-
Clay minerals tional films; and the distribution of pillars and of metal nanoparticles in the interlayer space for application
Clay–polymer nanocomposites as catalysts. Natural clay minerals suffer from several disadvantages, such as the presence of impurities and
Clay mineral films inhomogeneities in sizes and shapes of particles and in charge distribution. Synthesis of clay minerals with
Catalysis well-defined sizes and shapes of the particles and with homogeneous charge distribution is imperative to
obtain significant advancement of knowledge.
© 2015 Elsevier B.V. All rights reserved.

1. Introduction 2. Clay–polymer nanocomposites

“The production of clay minerals for industrial and environmental CPN's have been studied intensively for more than 20 years. The ear-
uses continues to grow annually and new applications of clays are an lier work has been reviewed extensively by Ray and Okamoto (2003).
exciting area of research and development. Sorbent clays, pillared More recently, several chapters in the handbook of Clay Science
clays, swelling clays and surface modified clays all have applications in (Bergaya et al., 2013; Detellier and Letaief, 2013; Lambert et al., 2013;
the expanding environmental markets such as landfills, fluid barrier ap- Ruiz-Hitzky et al., 2013) and a CMS workshop have also been devoted
plications, selective ion sorption and others. The major industrial appli- to CPN's (Carrado and Bergaya, 2007).
cations of clays are still expanding including uses in paper, paint, CPN's are expected to have improved mechanical properties, im-
plastics, ceramics, drilling fluids, foundry bondants, catalysts, agricul- proved heat stability and improved gas barrier properties with respect
ture, construction materials, pet litters, sorbents for oil and water spills to those of the neat polymer. In many applications the transparency of
and many others. The outlook for the future of applied clay science is in- the CPN's is also an issue and one has to control the optical properties
deed bright and hopefully we, the members of AIPEA, can cooperate to of the CPN's too. In particular, the light scattering has to be minimized.
make AIPEA the focus of international research and development of These improvements depend on (1) the dispersion of the clay mineral
clays and clay minerals for clay science” (Murray, 1994). layers and particles in the polymer matrix; (2) the nature and strength
These words were written by H. Murray in 1993 as incoming presi- of the clay mineral–polymer interactions; and (3) the properties of the
dent of AIPEA. They are prophetic indeed and still valid today. At that clay mineral itself such as the shape of the layers and particles, the
time the emphasis was clearly on the role of clays and clay minerals in amount and location of the isomorphous substitution, and the number
environmental science and technology. Now, 22 years later, the envi- and type of edge sites.
ronmental scope of clays and clay minerals is supplemented by in- In the successful preparation of CPN's the hydrophobic/hydrophilic
creased interest in research and development in at least 3 areas: properties of polymer and clay minerals have to be matched. This is
(1) clay–polymer nanocomposites (CPN), including clay–biopolymer most easily done by exchange of the clay mineral with alkylammonium,
nanocomposites; (2) hybrid clay mineral films with special optical and alkyl phosphonium and alkylpyridinium cations. Smectites are then the
electrochemical properties; and (3) heterogeneous catalysis, including preferred clay minerals. The d001 spacing increases upon exchange of
bioreactive clay minerals. these alkylcations. This has two advantages: (1) polymer chains can
more easily diffuse in the interlayer space; and (2) as a consequence
the d001 spacing might increase to such an extent that exfoliation occurs.
The CPN's contain then individual smectite layers and clay mineral par-
E-mail address: Robert.schoonheydt@biw.kuleuven.be. ticles of various sizes i.e. composed of 2, 3 or more layers.

http://dx.doi.org/10.1016/j.clay.2015.12.005
0169-1317/© 2015 Elsevier B.V. All rights reserved.
108 R.A. Schoonheydt / Applied Clay Science 131 (2016) 107–112

One might intuitively think that complete dispersion or complete while it is Na+ for F-hectorite and the charge density of mica is twice
exfoliation i.e. up to individual layers is the ideal to be achieved. It max- that of F-hectorite.
imizes the number of clay mineral layers in the polymer matrix and it Particles with a thickness of less than 20 nm cannot yet be measured
maximizes the contact and interaction between the clay mineral sur- with this AFM technique. Such thin particles tend to be sucked into the
faces and the polymer molecules. However, the mechanical properties gaps of the substrate (Fig. 2) and to be huddled against the wall of the
of individual clay mineral layers, 0.96 nm thick, are unknown. Sato substrate. This is an indirect proof of the easy bending and curling of sin-
et al. (2001) have performed a molecular dynamics (MD) simulation gle layers and of particles less than 20 nm thick or consisting of 2–15
on a single layer of beidellite with composition [Si31/3 Al2/3]IV[Al2] layers.
O10(OH)2Na2/3. They found that a compression in the A direction by The search for optimum dispersion of the clay mineral layers and
3–40% leads to a curved layer, which breaks up once the compression particles is a research topic of primary importance. This optimum dis-
exceeds 40% (Fig. 1). This curving is mainly due to a change in Si–O–Si persion will depend on the size, shape, charge density and hydration
bond angles and not to a change of bond lengths. This indicates that of the clay mineral layers. It will be different for Laponite than for mont-
under external forces in a polymer matrix single layers might easily morillonite, saponite or hectorite. Recent studies on 1:1 clay minerals
bend or curl. Measurement of the mechanical properties of single layers such as kaolinite might also be inspirational.
of natural smectites to confirm these predictions are extremely difficult Several strategies can be followed to prepare CPN's from kaolinite,
to perform. The reasons are multifold: (1) presence of impurity particles but they all start with a pre-intercalate (Detellier and Letaief, 2013;
on the clay mineral layers; (2) ill-defined edges of the layers and parti- Detellier and Schoonheydt, 2014). Exfoliation can be achieved, produc-
cles; (3) heterogeneity of the charge distribution in the layers; (4) non- ing single layers of kaolinite in the form of nanorolls or nanotubes. This
uniform hydration of the layers in the clay mineral particles; (5) irregu- is a very interesting observation. It shows that single layers of 1:1 clay
lar stacking of the layers in the particles. minerals curl into nanotubes. At the basis is the difference in bond
Kunz et al. (2009) measured the deformation of particles of a syn- lengths between Si–O bonds in the tetrahedral sheet, typically
thetic Fluor-hectorite (F-hectorite) by atomic force microscopy (AFM). 0.162 nm, and Al–O bonds in the octahedral sheets, typically
F-hectorite is obtained by melt synthesis and consists of up to 10 μm 0.187 nm. Imogolite and halloysite are 1:1 nanotubes which exist in na-
crystals. The individual layers are aligned perfectly parallel in the parti- ture. Single layers of 2:1 clay minerals such as smectites do not curl into
cles and have a uniform charge density. The particles have sharp edges nanotubes. The same differences in bond lengths of Si–O bonds on one
and a smooth well-defined morphology. The bending elasticity along hand and Al–O or Mg–O bonds on the other hand exist, but the octahe-
the c*-direction is measured to be C33 = 21 ± 9 Gpa, assuming that dral sheet is sandwiched between two tetrahedral sheets, preventing
the particle is clamped on both sides and 48 ± 20 GPa under the as- curling up of single layers into nanotubes. The expectation is that the
sumption that the particle is free i.e. not clamped on both sides. These single 2:1 layers do not spontaneously curl into nanotubes, but that
numbers have to be compared with those of rectorite, 18.3 ± 4.6 GPa they are easily bent. When deposited on a surface they will adapt their
and micas, 54.9–70.5 GPa. The differences in the numbers can be attrib- shape to the shape (roughness) of that surface. In a polymer matrix
uted to hydration, charge density and nature of the charge-compensat- the shape of the single layers of 2:1 clay minerals such as smectites is
ing cation. F-hectorite is a one layer hydrate with d001 = 1.23 nm. In determined by the interaction with the polymer chains. If the interac-
rectorite half of the interlayers are one layer hydrates. In micas there tion of the single layer–polymer chain is weak, the polymer acts as a sol-
is no interlayer water. The charge compensating cation is K+ in micas, vent. If the interaction of the single layer–polymer is strong, a smectite–
polymer complex is present in the CPN and the mechanical properties of
the CPN are expected to be different from those of the neat polymer and
the neat clay mineral.
Nacre is an extremely hard natural material composed of inorganic
nanoparticles cemented together by polymeric molecules. One would
like to prepare artificial nacre, which could eventually be used as a
bone implant. Clay minerals, in particular smectites, could be and have
been used to construct such artificial nacre-like implants. The composite
has a “brick-and-mortar” structure (Fig. 3), the bricks being the smectite
particles and the polymeric chains act as mortar. Such a brick-and-
mortar structure can be obtained by layer-by-layer (LbL) assemblage
in which layers and particles of Na-montmorillonite and of a cationic
polymer such as PDDA (PDDA = poly(diallyldimethylammonium))
are alternately deposited and held together by electrostatic and van de
Waals forces (Podsialdo et al., 2005). Such structures can absorb quite
a lot of energy. Upon deformation the layers of montmorillonite might

Fig. 1. Schematic drawing of the basic cell structure of beiddelite: the A-type cell includes a Fig. 2. AFM set-up to measure the mechanical properties of F-hectorite: The F-hectorite
18 × 3× 1 A-bending layer; the B-type cell includes a 6 × 12 × 1 B-bending layer. particles are shown as hexagons lying over the 2 μm wide channels of the substrate.
Adapted from Sato et al. (2001) with permission of ACS. Adapted from Kunz et al. (2009) with permission Of ACS.
R.A. Schoonheydt / Applied Clay Science 131 (2016) 107–112 109

Fig. 3. Schematic drawing of the brick-and-mortar structure to mimic nacre: open laths are the clay mineral particles (bricks); curved thick lines represent the polymer molecules (mortar)
and the solid thick line at the bottom is the substrate.

slide over each other and the polymer undergoes conformational mineral film preparation is to achieve a dual organization: (1) at the
changes. Thus, it is a strong and soft material. LbL assemblage is time- level of the clay mineral layers; and (2) at the level of the molecules in
consuming. Alternatives have been proposed. Walther et al. (2010) the interlayer spaces. The combination of a clay mineral layer and a
self assembled clay mineral layers and particles with soft polymer coat- monolayer of molecules is called a bilayer. Ideal cases of this two-level
ing into aligned nacre-mimetic films with a tensile modulus of 45 GPa organization are shown in Fig. 4. Such ideal films require (1) complete
and a tensile strength of 250 MPa by techniques derived from the exfoliation of the clay mineral particles into individual layers; (2) depo-
paper-making industry. Liff et al. (2007) prepared nanocomposites sition of these clay mineral layers all oriented in the same direction and
with Laponite in a solvent-exchange processing technique. not overlapping; (3) formation of monolayers of functional molecules in
The considerations exposed in this section lead to the following the interlayer spaces; and (4) in multilayers all bilayers should be
conclusions: identical.
Such ideal films have not been obtained yet. One comes closest to it
1. Carefully synthesized clay minerals with uniform charge density and with layer-by-layer (LbL) assemblage and the Langmuir–Blodgett (LB)
uniform size of layers and particles would be very useful for a funda- technique. Multilayered LbL films have rough surfaces and overlapping
mental study of the interaction between alkylcations and clay miner- clay mineral layers, although the average amount of deposited clay min-
al surfaces, between polymeric molecules and organoclays. With this eral layers and deposited molecules is identical in each bilayer of the
knowledge factors determining the optimum dispersion of the multilayered film (Van Duffel et al., 1999; Szabo et al., 2007). With the
organoclays in the polymeric matrix could be qualitatively and quan- LB technique a bilayer is formed at the air–water interface of the LB
titatively understood. trough. These bilayers can be deposited on a substrate and multilayers
2. There is a need to know the mechanical properties of single layers of are formed by repetition of this process. Also these LB films show sur-
clay minerals and their change upon adsorption of alkylcations and face roughness. This is due to (1) incomplete coverage of the substrate
polymers. With that knowledge one can apply a bottom–up ap- by the bilayer; (2) the presence of clay mineral layers and particles i.e.
proach and study the change of the mechanical properties of single incomplete exfoliation; (3) overlapping clay mineral layers; and
layers upon addition of layers, one at a time. An interesting question (4) slow diffusion of clay mineral layers into the aqueous dispersion
is if free floating 1:1 and 2:1 clay minerals layers are flat or whether due to gravitational forces during the bilayer preparation process
they spontaneously curl into nanotubes. If the latter occurs, what is (Szabo et al., 2009).
the minimum number of layers in a clay mineral particle in order If functional films have to be prepared, the functionality (e.g. dipole
to obtain a flat, two-dimensional particle? moment) is carried by the molecules in the interlayer spaces. These
molecules must then be organized in the interlayer space in such a
3. Clay mineral films way that the desired macroscopic property (functionality) is generated
in the film. In the case of dyes aggregation must be avoided and – gen-
Clay mineral films have been the subject of intensive research in the erally speaking – interaction between the adsorbed molecules and clay
last 20 years or so. This research has recently been reviewed (Zhou et al., mineral surfaces must be maximized and interaction between the
2011; Suzuki et al., 2012; Schoonheydt, 2014). The ultimate goal of clay adsorbed functional molecules themselves must be minimized. Several

Fig. 4. Schematic drawing of possible organizations of alkylammonium cations in the interlayer space.
110 R.A. Schoonheydt / Applied Clay Science 131 (2016) 107–112

strategies are offered in the literature: (1) dilution of amphiphilic opti- minerals is not an easy task. Clay minerals are layered materials,
cally active Ru(II) complexes with alkylammonium cations (Umemura which collapse, when the reaction temperature exceeds 100 °C. For
et al., 2002); (2) matching of the distances between positive charges acid catalysis two strategies have been developed to achieve this goal:
on porphyrins and the average distance between the negative charges acid activation and pillaring.
in the clay minerals (Takagi et al., 2006); and (3) improvement of the Acid activation partially dissolves the clay mineral lattice, creates
planarity of the π-electron system of the adsorbed dyes upon adsorption Brönsted and Lewis acid sites and increases the pore volumes and sur-
on the clay mineral surfaces (Suzuki et al., 2012). face areas of the catalysts into the domain of zeolites, typically to
The two-dimensional organization of functional molecules in the in- 0.10–0.20 cm3/g and 200–300 m2/g respectively. Acid activated clays
terlayer space is more demanding than the one-dimensional organiza- are commercially available (K10, KSF) and have been investigated at
tion in the channels of zeolites, such as zeolite L (Calzaferri et al., the laboratory scale in a variety of organic reactions (Adams and
2010; Calzaferri, 2012; Fois et al., 2013; Devaux et al., 2013) In zeolite McCabe, 2006). The downside of acid activation is that the activated
l the molecules are designed to be 0.72–0.75 nm thick, which is also clay mineral catalyst is very complex. It consists of partially disrupted
the free diameter of the channels. With these sizes the molecules cannot clay mineral structures and some amorphous silica, alumina and/or sil-
pass each other in the channels and a well organized system can be ica–alumina. The acid sites are Brönsted acid sites and Lewis acid sites of
built. This is shown in Fig. 5 with donor (D) and acceptor various nature and strength. As a consequence acid activated clay min-
(A) molecules, necessary to build fluorescence resonance energy trans- eral catalysts are susceptible to unwanted side reactions and coke
fer (FRET) systems. In the interlayer space of clay minerals there is in formation.
principle no limit on the size of the molecules, because of the swelling. Pillaring is the introduction of metal oxide pillars in the interlayer
However, the molecules can diffuse in the interlayer space and rear- space of smectites. The best known examples are the aluminium oxide
range. It will therefore be more difficult to build organized systems. pillars. The clay mineral is exchanged with a partially hydrolyzed solu-
Optimal (ideal) clay mineral films are difficult to prepare with natu- tion of Al3+, containing predominantly [Al13O4(OH)24(H2O)12]7+ with
ral smectites. This is mainly due to the heterogeneity of natural clay Keggin ion structure. After washing, drying and calcination the Keggin
minerals, heterogeneity in sizes and shapes of the particles and layers, ions in the interlayer space are transformed into Al2O3 pillars. Surface
in organization of the layers in the particles, in charge distribution, areas and pore volumes are significantly increased in comparison with
and in the presence of impurities. Synthetic clay minerals offer an alter- those of the parent smectite (Table 1). The pores are mainly micropores,
native. Some are commercially available: Laponite, Smecton, Kunipia F, indicating that a micropore system has been created in the interlayer
Kunipia P, F-hectorite. Careful synthesis in the lab is however required space. These Al-pillared clays or Al-PILC's can be used as acid catalysts
(Breu et al., 2001) to obtain homogeneous materials which can be sub- in hydrocarbon conversions. They contain Brönsted and Lewis acid
jected to fundamental studies. An additional advantage is that synthetic sites, covering a wide range of acid strengths. Pillaring has gone far be-
smectites can be prepared with transition metal ions in the octahedral yond Al. Fe, Ga, Ti and other metal ions have been used for pillaring
sheets. Thus, electron transfer and energy (photon) transfer from the often in combination with Al. The catalysis is not only restricted to hy-
transition metal ions in the octahedral sheets to adsorbed functional drocarbon conversions, but photocatalytic reactions and reactions for
molecules and vice versa can be studied. environmental clean-up have been extensively studied (Schoonheydt
Finally, the films, once prepared, must be mechanically stable; stable and Jacobs, 2006; Gil et al., 2000, 2010).
in environmental conditions such as humidity and – in the case of films Clay minerals are also redox catalysts. An example is the complete
in optical devices – the light scattering must be minimized and ulti- mineralization of organic pollutants through catalytic ozonation
mately eliminated. LbL films acting as oxygen barriers and with flame (Shahidi et al., 2015). This catalysis requires Fe, which is one of the
retardant properties have been prepared and studied (Priolo et al., most intensively studied elements in clay minerals. Structural Fe3+ in
2010; Li et al., 2010; Jang et al., 2008). The group of Kawamata obtained the octahedral sheets can be reduced to Fe2 +. This reduction affects
films with very low light scattering by optimization of the size of the the hydration of the clay mineral surfaces, the Si–O bond strengths
clay mineral particles, the mass% of clay mineral in the dispersion, and and the surface acidity (Stucki, 2006). Reduction of Fe increases the neg-
dissolution of dyes in an organic solvent (Suzuki et al., 2012). ative charge density of the clay mineral lattice. As a consequence the
structural oxygens become more basic. Reduced Fe containing clay min-
4. Clay mineral catalysts erals are more active than oxidized clay minerals in degradation of pes-
ticides, dechlorination of chlorinated hydrocarbons, and reduction of
There are 3 important parameters for heterogeneous catalysts: nitroaromatics. A plausible mechanism is that the chlorinated hydrocar-
(1) surface areas, pore volumes and pore sizes; (2) number, distribution bons interact with the lattice oxygens via the adsorbed water molecules.
and strength of active sites; and (3) stability and ability to regenerate The protons of water are strongly attracted to the more basic oxygens of
the catalysts. Zeolites are considered as ideal catalysts. They are crystal- the surface of the clay mineral layers. The oxygen atom of the water
line, three-dimensional solids with crystallographically defined micro- molecules carries excess negative charge and interacts with the H
porosity. The active sites are also crystallogaphically defined: the atom of the chlorinated hydrocarbon, thus producing adsorbed H3O+
acidic bridging OH group (Si–OH–Al), transition metal ions and their cations. The negative side of the reduction of structural Fe is that the re-
oligomeric clusters. To match these properties of zeolites with clay duction causes partial collapse of clay mineral layers, thus reducing the
accessibility of the surface for reagents.

Table 1
Typical surface areas and pore volumes of pillared montmorillonite.

Pillaring cation BET surface areas Pore volumes

m2/g cm3/g

Al 250–340 0.091–0.132
Ti 280 0.154
Zr 270 0.094
Fig. 5. Schematic drawing of possible arrangements of donor (D) and acceptor
Fe 200–270 0.082–0.148
(A) molecules in the interlayer space of clay minerals (left) and in the channels of zeolite
Cr 240–286 0.015–0.090
L (right).
R.A. Schoonheydt / Applied Clay Science 131 (2016) 107–112 111

Table 2 Table 3
Coupling reactions between azides and alkynes catalyzed by Cu nanoparticles on mont- Heck reactions catalyzed by Pd on montmorillonite. Adapted from Dutta et al. (2015) with
morillonite. Adapted from Dutta et al. (2015) with permission of Taylor & Francis. permission of Taylor & Francis.

This fascinating chemistry of Fe-containing clay minerals opens per-


spectives for synthetic clay minerals with other transition metal ions in pillars and their distribution in the interlayer space. Is it a single Al13
the octahedral or tetrahedral sheets. Cobalt is the most obvious choice Keggin ion which is transformed into a Al2nO3n pillar or two or more?
because it has two oxidation states, +2 and +3, such as Fe, and Co2+ (2) Is it possible to control the distribution of active sites in the interlay-
likes to coordinate both in tetrahedral and octahedral symmetry. Mn, er space so as to make them all available for reaction? (3) Is it possible to
Cr and V are other candidates, but these cations have more than 2 stable prepare shape-selective catalysts from clay minerals? Intercalation and
oxidation states. ordering of molecules in the interlayer space of synthetic F-hectorite has
Transition metal ions can of course be exchanged in the interlayer been shown (Stöter et al., 2013). The synthesis of clay minerals with
space of clay minerals. Such transition metal ion (TMI) exchanged clay transition metal ions in the octahedral and/or tetrahedral sheets is an-
minerals are also redox catalysts. The best known examples are the Fe- other advantage. The example of Fe (Stucki, 2006) illustrates the poten-
and Cu- exchanged clay minerals which polymerize pyrrole to polypyr- tial of these materials as catalysts.
role, a reaction which has been observed and studied a long time ago by
Pinnavaia and Mortland (1971). To prevent collapse of the clay mineral
5. Conclusions
layers low temperatures reactions with transition metal ion complexes
must be realized. Clay minerals have an advantage over zeolites in that
For the 3 research areas briefly discussed in this paper, carefully syn-
there is in principle no limit to the size of the complexes. Bulky complexes
thesized clay minerals are an advantage. They allow a fundamental
can be adsorbed which are too big to enter the micropores of the zeolites.
study of clay mineral–polymer interactions, of intercalation and organi-
Thus heterogenization of enzymes is an area worthwhile to be investigat-
zation of adsorbed molecules in the interlayer space, of pillaring and
ed in detail in order to develop heterogenized biocatalysts.
acid activation. This fundamental knowledge is necessary for making
Clay minerals can also be used as supports of metal nanoparticles,
significant progress towards application of clay minerals in industry.
which are catalysts in synthesis of fine chemicals. Metal ions are intro-
Special attention should be given to “new” clay minerals or synthetic
duced by ion exchange or impregnation and reduced by a variety of
clay minerals which do not have a natural counterpart, such as transi-
methods. A high surface area is required to stabilize the metal nanopar-
tion metal ion containing clay minerals with prospects in catalysis. In
ticles and thus acid activated clay minerals are the first choice, although
the area of clay mineral–polymer composites special attention should
PILC's have also been used. A variety of reduction methods is reported
be given to immobilized enzymes and their conformation in the
(Dutta et al., 2015), but the metal nanoparticles must be prevented
adsorbed state. This determines whether the catalytically active sites
from sintering into large particles. The catalytic reactions studied in-
of the enzyme are accessible by reactants and thus whether reaction
clude oxidations of pollutants, hydrogenations, such as the reduction
can occur.
of the nitro group to NH2. Quite interesting is the potential of metal
nanoparticles/montmorillonite catalysts in coupling reactions and syn-
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