Effect of Process Conditions on the Properties of Resorcinol-Formaldehyde Aerogel Microparticles Produced via Emulsion-Gelation Method

Organic aerogels in the form of powder, microgranules and microsized particles receive considerable attention due to their easy fabrication, low process time and costs compared to their monolithic form. Here, we developed resorcinol-formaldehyde (RF) aerogel microparticles by using an emulsion-gelation method. The main objective of this study is to investigate the influence of curing time, stirring rate, RF sol:oil ratio and initial pH of the sol in order to control the size and properties of the microparticles produced. The emulsion-gelation of RF sol prepared with sodium carbonate catalyst in an oil phase at 60 °C was explored. RF microparticles were washed with ethanol to remove the oil phase followed by supercritical and ambient pressure drying. The properties of the dried RF microparticles were analyzed using FT-IR, N(2) adsorption isotherm, gas pycnometry, wide angle X-ray scattering and scanning electron microscope. RF microparticles with high surface area up to 543 m(2)/g and large pore volume of 1.75 cm(3)/g with particle sizes ranging from 50–425 µm were obtained.