Clay-based durable catalyst membranes of porous layered double hydroxide and gold nanoparticle nanocomposites for fast and continuous-flow reactions

Abstract

We synthesized the hybrid catalyst of a porous layered double hydroxide (LDH) decorated with ultrasmall Au nanoparticles. The porous LDH was prepared by coprecipitation and ethanol washing, producing thin LDH nanoplatelets. Thereafter, spray drying was carried out, affording a few hundred nm of the hydrangea-like structure of the LDH with an extensive open network and a Brunauer–Emmett–Teller surface area of 386 m2/g. Its sizable open frame and active hydroxide surface enabled the uniform decoration of average 4-nm-diameter Au nanoparticles (Au/P-LDH) through one-pot chemical reduction using NaBH4 at room temperature. We applied the Au/P-LDH for the fabrication of catalyst membranes, which are potentially valuable for the continuous flow of catalytic reactions, e.g., the hydrogenation of p-nitrophenol. This study suggested that their porous structure and active Au nanoparticle catalyst allowed fast and mass catalytic functions by simple filtration without washing or catalyst recovery steps. We found no significant damage to the hybrid membrane during the reactions with a few liters; thus, we expect strong bindings of the Au nanoparticles on the surface of the porous LDH.