Kinetics and mechanism of the formation of doped skeletal copper catalysts: the effect of zincate compared to undoped and chromate-doped systems

Addition of zincate to the leach liquor for the preparation of skeletal copper increases the copper surface area; however it does not stabilize the structure against rearrangement. The leaching kinetics have been studied using a rotating disc electrode (RDE) at 269–293 K in 2–8 M NaOH and 0.0005–0.1 M Na₂ZnO₂. Zincate ions precipitate as zinc oxide, due to the local consumption of hydroxide ions near the leach front as the aluminium dissolves. This oxide hinders the aluminium dissolution, slowing the leaching rate. It also hinders copper dissolution/redeposition and prevents copper diffusion, thus reducing the structural rearrangement significantly, and causing the formation of a much finer copper structure with increased surface area. The zinc oxide redissolves as the leach front passes, releasing the copper to rearrange once more, thereby allowing the surface area to decrease with time. The activation energy for leaching was found to be 84 ± 6 kJ mol^–1.