Controllable particle sizes of spherical carbon from resorcinol-formaldehyde used as a support materials

Carbon is frequently employed as a catalyst or catalyst support due to its favorable characteristics, including a substantial specific surface area, a considerable quantity of pores, robust electron conductivity, chemical inertness, and cost-effectiveness. The current study examines the synthesis of colloidal spheres of resorcinol-formaldehyde (RF) resin through a polymerization process of RF in a blend of ethanol, water, and aqueous ammonia. The process bears a resemblance to the Stober technique for synthesizing silica spheres. Ammonia promotes RF polymerization from inside droplets, resulting in homogenous colloidal spheres. The spherical carbon precursor was carbonized in N₂ gas at 800 °C. The findings indicate that the carbon samples exhibited a spherical morphology and separated into distinct particles. SEM images illustrate that the dimensions of the carbon colloidal spheres exhibited variation, ranging from 245 to 985 nm, contingent upon the concentration of alcohol and ammonia. EDS analysis of the samples indicated a carbon purity exceeding 90%wt, while the XRD pattern verified the structure using a 2θ range of 10° to 60°, showing a significant peak intensity at 23.5° that corresponds to graphitic carbon. Using BET methodology, the range of the specific surface area was between 519 to 812 m²/g. Control of particle size with a spherical morphology was achievable through regulation of alcohol and aqueous ammonia quantities, resulting in a facile and economically effective production methodology.