1. Introduction
The need for sustainable energy solutions has stimulated the development of techniques for reusing scarce resources and achieving high-energy storage capabilities [
1,
2]. The efficient utilization of earth-abundant transition-metal-based materials can fulfill these requirements, due to their cost-effectiveness and high activity [
3,
4,
5,
6]. Recently, lithium-ion batteries (LIBs) have been developed for a wide range of electronic applications due to their high specific capacitance, low cost, and reversible redox properties [
7,
8,
9,
10]. Such LIBs can be developed from transition metal hydroxides. The selective synthesis of metal hydroxides not only improves the formation efficiency of conventional metal materials but also has great significance in producing new metal materials.
Among these metal hydroxides, nickel hydroxides with electronic properties and a two-dimensional layered structure are widely employed for batteries [
7,
8,
9,
10,
11] and electrocatalysts [
12,
13,
14,
15,
16,
17]. Nickel hydroxides have three possible crystal structures:
α,
β, and
γ phases. Among them,
α-nickel hydroxide, which has a disordered amorphous structure, accommodates various anions and water molecules within the interlayer space due to its border interlayer space [
18,
19], providing electrochemical properties superior to those of
β-nickel hydroxide [
20]. Although
α-nickel hydroxide is a valuable precursor for metallic materials, its isolation is challenging due to its rapid conversion to
β-nickel hydroxide. Several synthetic methods for
α-nickel hydroxide have been reported, including electrolysis using urea [
17], the sonochemical method [
21], and the solvothermal process [
22]. In particular, solvothermal methods are attractive because they are simple and can be easily applied to various fields; however, such methods are fewer compared to other methods.
Solution-based synthetic approaches for producing metal compounds offer substantial advantages over electrolysis [
23], providing control over size, shape, and product distribution. Among these procedures, the polyol process represents a straightforward method for generating various metal particles [
24,
25,
26,
27,
28], minimizing the emission of toxic gases during thermal decomposition and preventing contamination of the products by reductants. In a typical polyol process, the conversion of metal ions to metal hydroxides is followed by the reduction of metal hydroxides to metal particles. Ethylene glycol, which is commonly employed in the polyol process, acts not only as a solvent but also produces acetaldehyde as a reducing species, facilitating the reduction of metal hydroxides to metal particles. Because of the rapid progression of such a polyol process, it is difficult to isolate valuable metal hydroxides. Jeyadevan et al. postulated that the formation of metal alkoxide complexes between metal and ethylene glycol is the rate-determining step for the progress of the polyol process [
27]. In the present report, the efficient formation of metal reaction intermediates is hypothesized to be the key reaction for selective synthesis of the metal hydroxide. Based on this knowledge, we attempt to adjust ethylene glycol-derived anion or dianion to efficiently generate nickel reaction intermediates, which delay the formation of nickel hydroxide (
Figure 1).
This report describes a novel polyol process-based procedure for the selective synthesis of α-nickel hydroxide. An examination of various reaction conditions revealed that the optimum procedure was the addition of a solution of nickel sulfate or nitrate in ethylene glycol to a solution of sodium hydroxide in ethylene glycol. The reaction solution was stirred at 200 °C for 2 h under an argon atmosphere, resulting in the generation of α-nickel hydroxide as the main product. X-ray diffraction (XRD), infrared (IR), and thermogravimetric (TG) analyses of the obtained α-nickel hydroxide indicated intercalation of ethylene glycol molecules between the layers. Based on the estimated Gibbs free energies for stepwise reactions, employing density functional theory (DFT) calculations, some nickel reaction intermediates between nickel ion and ethylene glycol were assumed to contribute to the delay in the formation of α-nickel hydroxide, consequently suppressing the generation of metallic nickel. The polyol process shown in this study is expected to be applied to the making of various metal hydroxides in the future.
2. Materials and Methods
Infrared absorption (IR) spectra were recorded using an FT/IR-4600 series by JASCO Corporation (Tokyo, Japan). X-ray powder diffraction (XRD) patterns were recorded on a Rigaku Corp. (Tokyo, Japan) Ultim Ⅳ, using Cu Kα radiation operated at 40 kV and 10 mA. Transmission electron microscopy (TEM) images were taken on a Hitachi High-Tech Corp. (Tokyo, Japan) HT7700 operated at 112 kV. Scanning electron microscopy (SEM) images were obtained with a Hitachi High-Tech Corp. TM3030. Thermogravimetric analyses were measured using a Seiko Instrument TG-DTA (Shimazu Corp. DTG-60, Kyoto, Japan) under a nitrogen flow rate of 100 mL/min, in a range from 50 to 600 °C at a heating rate of 10 °C/min.
Ethylene glycol (EG) (>99.5%), glycerol (Gly) (>99.5%), nickel (Ⅱ) chloride hexahydrate (>98%), nickel (Ⅱ) nitrate hexahydrate (>98%), nickel (Ⅱ) sulfate hexahydrate (>99%), potassium hydroxide (>85%), sodium hydroxide (>97%), and tetraethylene glycol (TEG) (>95%) were purchased from FUJIFILM Wako Pure Chemical Co., Ltd. (Osaka, Japan). Poly-ethylene glycol (Poly-EG) (average Mn = 400) and 0.45 μm PTFE membrane filter were purchased from Sigma-Aldrich Co., LLC. (Burlington, MA, USA) and used as received. All solvents, such as EG, TEG, Poly-EG, and Gly, were degassed prior to use.
2.1. Synthesis of Metallic Nickel
A solution of nickel(Ⅱ) sulfate hexahydrate (1.051 g; 3.998 mmol) in EG (10 mL) was adjusted using a heat gun and filled into a 20 mL syringe. This prepared reaction solution was added at once to a solution of sodium hydroxide (320 mg; 8.00 mmol) in EG (20 mL) in a two-necked 100 mL flask under an argon atmosphere and the reaction solution was stirred at 200 °C for 2 h. After finishing it, the resulting precipitation was washed with distilled water, collected with a suction filtration through a membrane filter, and dried at room temperature for 12 h under reduced pressure to obtain a black–green powder (112 mg) as a metallic nickel. XRD (2θ): 44.5°, 51.9°, 76.4°, and 93.1°.
2.2. Synthesis of α-Nickel Hydroxide
In a 100 mL flask, a solution of sodium hydroxide (320 mg; 8.00 mmol) in EG (10 mL) was stirred at room temperature for 12 h under an argon atmosphere. The separately adjusted solution of nickel(Ⅱ) sulfate hexahydrate (1.051 g; 3.998 mmol) in EG (10 mL) was added to the above-mentioned solution containing sodium hydroxide using a syringe. The reaction solution was stirred at 200 °C for 2 h and the resulting precipitation was washed with distilled water, collected with a suction filtration through a membrane filter, and dried at room temperature for 12 h under reduced pressure to obtain a bright green solid (440 mg) as a α-nickel hydroxide including EG. IR (ATR, cm−1) ν 3301, 2889, 2853, 1625, 1406, 1351, 1123, 1079, 1057, 876, 656, and 482. XRD (2θ): 10.7°, 34.2°, and 60.9°.
Experiments under various reaction conditions using the method B in Run 2 were investigated (
Table 1, Runs 3–12, Method).
In Run 3, the reaction of nickel(Ⅱ) sulfate hexahydrate (1.051 g; 3.998 mmol) with potassium hydroxide (1.280 g; 32.00 mmol) in EG (30 mL) was carried out at 200 °C for 2 h under an argon atmosphere to obtain a black solid (496 mg).
In Run 4, the reaction of nickel(Ⅱ) sulfate hexahydrate (1.051 g; 3.998 mmol) with potassium hydroxide (449 mg; 8.00 mmol) in EG (30 mL) was carried out at 200 °C for 2 h under an argon atmosphere to obtain a bright green (452 mg).
In Run 5, the reaction of nickel(Ⅱ) sulfate hexahydrate (1.051 g; 3.998 mmol) with sodium hydrogen carbonate (672 mg; 8.00 mmol) in EG (30 mL) was carried out at 200 °C for 2 h under an argon atmosphere to obtain a bright green (452 mg).
In Run 6, the reaction of nickel(Ⅱ) sulfate hexahydrate (1.051 g; 3.998 mmol) with sodium carbonate (848 mg; 8.00 mmol) in EG (30 mL) was carried out at 200 °C for 2 h under an argon atmosphere to obtain a bright green (345 mg).
In Run 7, the reaction of nickel(Ⅱ) sulfate hexahydrate (1.051 g; 3.998 mmol) with potassium carbonate (1.11 g; 8.03 mmol) in EG (30 mL) was carried out at 200 °C for 2 h under an argon atmosphere to obtain a black–green solid (484 mg).
In Run 8, the reaction of nickel(Ⅱ) sulfate hexahydrate (1.051 g; 3.998 mmol) with sodium hydroxide (320 mg; 8.00 mmol) in TEG (30 mL) was carried out at 200 °C for 2 h under an argon atmosphere to obtain a green solid (345 mg).
In Run 9, the reaction of nickel(Ⅱ) sulfate hexahydrate the reaction of nickel(Ⅱ) sulfate hexahydrate (1.051 g; 3.998 mmol) with sodium hydroxide (320 mg; 8.00 mmol) in Poly-EG (30 mL) was carried out at 200 °C for 2 h under an argon atmosphere to obtain a green solid (437 mg).
In Run 10, the reaction of nickel(Ⅱ) sulfate hexahydrate the reaction of nickel(Ⅱ) sulfate hexahydrate (1.051 g; 3.998 mmol) with sodium hydroxide (320 mg; 8.00 mmol) in Gly (30 mL) was carried out at 200 °C for 2 h under an argon atmosphere to obtain a dark green solid (437 mg).
In Run 11, the reaction of nickel(Ⅱ) chloride hexahydrate (951 mg; 4.00 mmol) with sodium hydroxide (320 mg; 8.00 mmol) in EG (30 mL) was carried out at 200 °C for 2 h under an argon atmosphere to obtain a black powder (218 mg). XRD (2θ): 44.8°, 52.2°, 76.7°, and 93.3°.
In Run 12, the reaction of nickel(Ⅱ) nitrate hexahydrate (1.163 g; 3.999 mmol) with sodium hydroxide (320 mg; 8.00 mmol) in EG (30 mL) was carried out at 200 °C for 2 h under an argon atmosphere to obtain a bright green solid (472 mg). XRD (2θ): 11.1°, 34.7°, and 61.0°.
A solution of sodium hydroxide (80 mg; 2.0 mmol) in EG (1 mL) was stirred at room temperature for 12 h and the reaction solution was concentrated under reduced pressure and dried at room temperature for 12 h to obtain crude EG-Na as a white powder.
3. Results
Reactions of nickel sulfate with a base were conducted under various reaction conditions for the selective synthesis of
α-nickel hydroxide as the main product (
Scheme 1). The results are presented in
Table 1. The reaction involving nickel sulfate and sodium hydroxide in ethylene glycol (EG) in situ was performed at 200 °C for 2 h under an argon atmosphere (Run 1). The resulting precipitate was collected through suction filtration, washed with distilled water, and then dried at room temperature under reduced pressure, yielding the product as a blackish-green solid. Its structure was confirmed by powder XRD analysis (
Figure 2).
The XRD patterns depicted in
Figure 2A are consistent with the theoretical data for metallic nickel without
α and
β-nickel hydroxides. This observation suggests that the polyol process employing method A proceeded efficiently with the conversion of nickel sulfate into metallic nickel. During the polyol process utilizing EG, the emergence of acetaldehyde via the condensation reaction of EG is widely acknowledged as a pivotal reductant [
25,
27,
28]. The crude reaction solution was analyzed by
1H NMR, IR, and ESI spectroscopies to confirm the presence of acetaldehyde and deacetyl as by-products, supporting the progress of this reaction through the polyol process. However, the peaks anticipated for each compound were not confirmed, indicating their removal from the reaction system because of their significantly lower boiling points compared to the reaction temperature.
Next, method B of the polyol process was performed, as shown in
Scheme 1 (Run 2). Sodium hydroxide and EG were stirred at room temperature for 12 h under an argon atmosphere to produce the sodium salt of ethylene glycol (EG-Na). Subsequently, a solution of nickel sulfate in EG was added to the prepared solution, resulting in a pale green precipitate. The powder XRD patterns depicted in
Figure 2B showed characteristic peaks at 10.8°, 34.2°, and 60.9° corresponding to (003), (101), and (110), respectively, derived from
α-nickel hydroxide, which agrees with the previously reported data [
18,
21]. The interlayer space along the c-axis was estimated from the position of each peak to be
d = 8.25 Å, 2.62 Å, and 1.52 Å, respectively. The interlayer space at (003) of the synthesized
α-nickel hydroxide was broader than those reported for
α-nickel hydroxides [
18,
21], suggesting intercalation of EG molecules between the layers of
α-nickel hydroxide. The reflection at
d = 2.62 Å indicates the formation of a turbostratic phase, a common feature in
α-nickel hydroxide. The three peaks at 20.5°, 45.2°, and 52.5° correspond to a glass plate. The IR spectra in
Figure 3A–D represent EG and the synthesized
α-nickel hydroxide, respectively. The broad peak from 2997 to 3694 cm
−1 in
Figure 3B indicates the hydroxyl groups of
α-nickel hydroxide, EG, and water. The two peaks attributable to the stretching vibration derived from the two methylene moieties of EG in
Figure 3B were confirmed at 2852 and 2886 cm
−1, with a shift to lower wavenumbers compared to those of the original EG in
Figure 3A, implying interactions between
α-nickel hydroxide and EG. A peak at 1631 cm
−1 corresponds to the vibration of the interlayer water molecules. The two peaks at 1056 and 1078 cm
−1 correspond to stretching vibrations of ether bonds in EG. In the comparison of
Figure 3C,D, a characteristic peak at 652 cm
−1 in the IR spectrum of
α-nickel hydroxide supported in-plane OH deformations. Additionally, a peak attributable to Ni-OH vibrations was observed at 484 cm
−1. These analytical results support the successful formation of
α-nickel hydroxide, inclusive of EG. To examine the effect of the amount of sodium hydroxide on the reaction behavior of the method B polyol process, an experiment involving 8-fold more sodium hydroxide than that used in conditions in Run 2 (Run 3) was conducted. As shown in
Figure 2C, the three peaks associated with
α-nickel hydroxide in the XRD patterns of the resulting product decreased significantly compared to those in Run 2 and those attributable to metallic nickel were also not clearly observed. These comparative results suggested that two equivalents of sodium hydroxide to nickel sulfate are suitable.
Based on the method used for Run 2, further controlled experiments were performed utilizing different bases and solvents (
Table 1, Runs 4–10). The XRD data for the obtained products are supplied in
Supporting Information (Figures S1–S3). The use of potassium hydroxide yielded a product with a highly amorphous structure, preventing its unequivocal identification by XRD analysis (Run 4). Reactions using sodium hydrogen carbonate or potassium carbonate, both soluble in EG, yielded
α-nickel hydroxides with lower intensity at 2θ = 10.8° compared to that in Run 2 (Runs 5 and 6). In contrast, the reaction using sodium carbonate, which is insoluble in EG, produced a mixture of
α-nickel hydroxide and metallic nickel (Run 7). The base choice strongly influenced the formation of the product. Substituting EG with other solvents, such as tetraethylene glycol (TEG), polyethylene glycol (Poly-EG, average
Mn = 400), and glycerol (Gly), produced little
α-nickel hydroxide, emphasizing the requirement for EG as a solvent (Runs 8–10). Analogous experiments involving nickel nitrate or nickel chloride as substitutes for nickel sulfate were also performed (Runs 11–12). Nickel nitrate underwent conversion into
α-nickel hydroxide, whereas nickel chloride was transformed into metallic nickel. Thus, the efficacy of this polyol process, employing method B, is contingent upon the nature of substrate.
Thermogravimetric analyses (TGA) of the synthesized
α-nickel hydroxide in Run 2 and a commercially available
β-nickel hydroxide were conducted in the range from 50 to 600 °C under an air atmosphere, as depicted in
Figure 4. The TG chart of
α-nickel hydroxide shows a gradual progression of thermal decomposition from commencement of the measurement, most likely due to vaporization of EG and water molecules on the surfaces and between the layers. The thermal degradation observed between 250 and 330 °C was attributed to the dehydration of hydroxy groups in
α-nickel hydroxide. The XRD patterns of the resulting sample after heating at 600 °C identified it as nickel oxide (NiO) (
Figure S4) with a residual weight of 66%, which agrees well with the previously reported residual weight (65%) [
21]. The thermal decomposition behavior of
β-nickel hydroxide was similar to that of
α-nickel hydroxide and its residual weight at 600 °C was 80%. The difference in thermal decomposition of the two different nickel hydroxides was due to the greater solvent content in
α-nickel hydroxide compared to that of
β-nickel hydroxide.
The dimensions and structure of the synthesized
α-nickel hydroxide in Run 2 were examined by transmission electron microscopy (TEM) and scanning electron microscope (SEM). The TEM images presented in
Figure 5 indicated that the synthesized
α-nickel hydroxide possesses fibrous structures without a definite shape. The size was estimated to be approximately 200 nm in length and 20 nm in width. The SEM images presented in
Figure 6 indicated that the synthesized
α-nickel hydroxide has the morphology of unshaped structures.