Synthesis of carbon nanotubes over nickel–iron catalysts supported on alumina under controlled conditions

Carbon nanotubes (CNTs) were synthesized by catalytic decomposition of acetylene over Fe, Ni and Fe–Ni catalysts supported on alumina. The growth of CNTs was carried out at various reaction conditions. The growth density and diameter of CNTs could be controlled by varying the catalyst composition and the growth parameters. The growth density of CNTs increased with increasing the activation time of catalysts in H₂ atmosphere and/or decreasing acetylene concentration. At 600°C, higher density of CNTs was observed at 60 min for higher Fe containing catalyst, whereas at 90 min for higher Ni containing catalyst. The growth density of CNTs highly increased with increasing reaction time from 30 to 60 min. For all the catalysts, the diameter of CNTs decreased with increasing growth time further mainly due to hydrogen etching. Bimetallic catalysts produced narrower diameter CNTs than single metal catalysts. The growth of CNTs followed the tip growth mode and the CNTs were multi-walled CNTs.     

Synthesis of narrow-diameter carbon nanotubes from acetylene decomposition over an iron-nickel catalyst supported on alumina

Carbon nanotubes (CNTs) were synthesized by the catalytic decomposition of acetylene over 40Fe:60Al₂O₃, 40Ni:60Al₂O₃ and 20Fe:20Ni:60Al₂O₃ catalysts. High density CNTs of 20 nm diameter were grown over the 20Fe:20Ni:60Al₂O₃ catalyst, whereas low growth density CNTs of 40 and 50 nm diameter were found over 40Fe:60Al₂O₃ and 40Ni:60Al₂O₃ catalysts. Smaller catalyst particles enabled the synthesis of highly dense, long and narrow-diameter CNTs. It was found that a homogeneous dispersion of the catalyst was an essential factor in achieving high growth density. The carbon yield and the quality of CNTs increased with increasing temperature. For the 20Fe:20Ni:60Al₂O₃ catalyst, the carbon yield reached 121% after 90 min at 700 °C. The CNTs were grown according to the tip growth mode. Based on reports regarding hydrocarbon adsorption and decomposition over different faces of Ni and Fe, the growth mechanism of CNTs over the 20Fe:20Ni:60Al₂O₃ catalyst are discussed.     

Catalytic growth of semiconductor micro- and nano-crystals using transition metal catalysts

The catalytic reaction concept was introduced in the growth of semiconductor micro- and nano-crystals. It was found that gallium nitride (GaN) micro- and nano-crystal structures, carbon nanaotubes, and silicon carbide (SiC) nanostructures could be efficiently grown using transition metal catalysts. The use of Ni catalyst enhanced the growth rate and crystallinity of GaN micro-crystals. At 1,100 ‡C, the growth rate of GaN micro-crystals grown in the presence of Ni catalyst was over nine times higher than that in the absence of the catalyst. The crystal quality of the GaN microcrystals was almost comparable to that of bulk GaN. Good quality GaN nanowires was also grown over Ni catalyst loaded on Si wafer. The nanowires had 6H hexagonal structure and their diameter was in the range of 30–50 nm. Multiwall nanotubes (MWNTs) were grown over 20Fe : 20Ni : 60Al₂O₃ catalyst. However, single wall nanotubes (SWNTs) were grown over 15Co : 15Mo : 70MgO catalyst. This result showed that the structure of CNTs could be controlled by the selection of catalysts. The average diameters of MWNTs and SWNTs were 20 and 10 nm, respectively. SiC nanorod crystals were prepared by the reaction of catalytically grown CNTs with tetrametysilane. Structural and optical properties of the catalytically grown semiconductor micro- and nano-crystals were characterized using various analytic techniques. This paper is dedicated to Professor Wha Young Lee on the occasion of his retirement from Seoul National University.     

Hydrogen Production by Steam Reforming of Commercially Available LPG in UAE

Steam reforming of commercially available LPG using Ru/Al₂O₃ and Ni/Al₂O₃ catalysts has been studied at temperatures between 573 and 773 K. Ru/Al₂O₃ catalyst showed higher rates of reaction and lower activation energies of the three main components of LPG, compared with Ni/Al₂O₃. However, Ni/Al₂O₃ catalyst showed a better H₂:CH₄ selectivity. The activation energy of n-butane was the lowest over Ru/Al₂O₃, whereas over Ni/Al₂O₃, propane had the lowest activation energy. The activation energy of i-butane was always the highest over both catalysts, which suggests that both catalysts performed better with unbranched molecules. A slight increase in activation energy was observed, when each component of the LPG mixture was studied separately as a pure gas, compared with being mixed in LPG. At a constant temperature of 773 K, hydrogen production yield and H₂:CH₄ selectivity were determined using Ru/Al₂O₃ at different steam:carbon (S:C) ratios and LPG flow rates. It was found that the yield and selectivity increased with the increase in S:C ratio and the decrease in the flow rate. The highest yield of 0.64 was achieved using S:C ratio of 6.5 and a LPG flow rate of 50 mL min^?1. The work provides valuable information on steam reforming of pure components of LPG, compared with when they are in the mixture. The comparison is done using conventional steam reforming catalyst, Ni/Al₂O₃, and compared with Ru/Al₂O₃. The observed trends and variations in reaction rates, in pure and mixed gases, indicated that the mechanism of steam reforming of a hydrocarbon mixture depends on its composition.     

Effect of adding nickel to iron-alumina catalysts on the morphology of as-grown carbon nanotubes

The synthesis of carbon nanotubes (CNTs) from ethylene decomposition by Fe/Al₂O₃ and Fe/Ni/Al₂O₃ catalysts (Fe:Ni=10:1) is studied. A small amount of nickel introduced into the catalyst can significantly increase the yield of CNTs, but the nanotubes change from straight tubes with concentric parallel carbon sheets to helical tubes of the fish-bone type. Raman characterization of CNTs prepared at 823 and 1023 K and CNTs annealed at 2473 K shows that CNTs deposited on the Fe/Ni/Al₂O₃ catalyst have poor crystallinity, as compared with that on the Fe/Al₂O₃ catalyst. These differences are explained by a mechanism of formation of helical tubes of the fish bone type that takes into consideration the differences in the chemical nature of the catalyst with and without nickel.     

Co-production of hydrogen and multi-wall carbon nanotubes from ethanol decomposition over Fe/Al2O3 catalysts

The co-production of hydrogen and carbon nanotubes (CNTs) from the decomposition of ethanol over Fe/Al₂O₃ at different temperatures and feeding rates of ethanol was investigated systematically. The results indicated that Fe/Al₂O₃ was a quite active catalyst for the co-production of hydrogen and CNTs and that its activity and stability depended strongly on the Fe loading. Among all catalysts tested, 10 mol% Fe/Al₂O₃ was the most effective catalyst based on the ratio of hydrogen production, the total H₂ yield, and the quality of the CNTs formed. The efficiency of hydrogen production from ethanol decomposition over 10 mol% Fe/Al₂O₃ reached a maximum of 80% at 800 °C and the yield of CNTs with well-oriented growth and uniform diameter was 141%. In addition, the reaction of hydrogen and CNTs co-produced from ethanol decomposition was proposed.     

Co-production of hydrogen and multi-wall carbon nanotubes from ethanol decomposition over Fe/Al2O3 catalysts

The co-production of hydrogen and carbon nanotubes (CNTs) from the decomposition of ethanol over Fe/Al₂O₃ at different temperatures and feeding rates of ethanol was investigated systematically. The results indicated that Fe/Al₂O₃ was a quite active catalyst for the co-production of hydrogen and CNTs and that its activity and stability depended strongly on the Fe loading. Among all catalysts tested, 10 mol% Fe/Al₂O₃ was the most effective catalyst based on the ratio of hydrogen production, the total H₂ yield, and the quality of the CNTs formed. The efficiency of hydrogen production from ethanol decomposition over 10 mol% Fe/Al₂O₃ reached a maximum of ∼80% at 800 °C and the yield of CNTs with well-oriented growth and uniform diameter was 141%. In addition, the reaction of hydrogen and CNTs co-produced from ethanol decomposition was proposed.     

Characterization of aerogel Ni/Al2O3 catalysts and investigation on their stability for CH4-CO2 reforming in a fluidized bed

The CH₄-CO₂ reforming was investigated in a fluidized bed reactor using nano-sized aerogel Ni/Al₂O₃ catalysts, which were prepared via a sol–gel method combined with a supercritical drying process. The catalysts were characterized with BET, XRD, H₂-TPR and H₂-TPD techniques. Compared with the impregnation catalyst, aerogel catalysts exhibited higher specific surface areas, lower bulk density, smaller Ni particle sizes, stronger metal-support interaction and higher Ni dispersion degrees. All tested aerogel catalysts showed better catalytic activities and stability than the impregnation catalyst. Their catalytic stability tested during 48 h reforming was dependent on their Ni loadings. Characterizations of spent catalysts indicated that only limited graphitic carbon formed on the aerogel catalyst, while massive graphitic carbon with filamentous morphology was observed for the impregnation catalyst, leading to significant catalytic activity degradation. An aerogel catalyst containing 10% Ni showed the best catalytic stability and the lowest rate of carbon deposition among the aerogel catalysts due to its small Ni particle size and strong metal-support interaction.     

Improvement of coke resistance of Ni/Al2O3 catalyst in CH4/CO2 reforming by ZrO2 addition

This work investigates the improvement of Ni/Al₂O₃ catalyst stability by ZrO₂ addition for H₂ gas production from CH₄/CO₂ reforming reactions. The initial effect of Ni addition was followed by the effect of increasing operating temperature to 500–700 °C as well as the effect of ZrO₂ loading and the promoted catalyst preparation methods by using a feed gas mixture at a CH₄:CO₂ ratio of 1:1.25. The experimental results showed that a high reaction temperature of 700 °C was favored by an endothermic dry reforming reaction. In this reaction the deactivation of Ni/Al₂O₃ was mainly due to coke deposition. This deactivation was evidently inhibited by ZrO₂, as it enhances dissociation of CO₂ forming oxygen intermediates near the contact between ZrO₂ and nickel where the deposited coke is gasified afterwards. The texture of the catalyst or BET surface area was affected by the catalyst preparation method. The change of the catalyst texture resulted from the formation of ZrO₂–Al₂O₃ composite and the plugging of Al₂O₃ pore by ZrO₂. The 15% Ni/10% ZrO₂/Al₂O₃ co-impregnated catalyst showed a higher BET surface area and catalytic activity than the sequentially impregnated catalyst whereas coke inhibition capability of the promoted catalysts prepared by either method was comparable. Further study on long-term catalyst stability should be made.     

The role of nickel in pyridine hydrodenitrogenation over NiMo/Al2O3

Al₂O₃ supported Mo, Ni, and NiMo/Al₂O₃ catalysts with various Ni contents were prepared to investigate the role of Ni as a promoter in a NiMo bimetallic catalyst system. The hydrodenitrogenation (HDN) reaction of pyridine as a catalytic probe was conducted over these catalysts under the same reaction conditions and the catalysts were characterized using BET surface area measurement, infrared spectroscopy, temperature programmed reduction, DRS and ESR. According to the results of reaction experiments, the NiMo/Al₂O₃ catalyst showed higher activity than Mo/Al₂O₃ catalyst in the HDN reaction and particularly the one with atomic ratio [Ni/(Ni+Mo)]=0.3 showed the best activity for the HDN of pyridine. The findings of this study lead us to suggest that the enhancement in the HDN activity with nickel addition could be attributed to the improvement in the reducibility of molybdenum and the formation of Ni-Mo-O phase.     

Efficient production of hydrogen and multi-walled carbon nanotubes from ethanol over Fe/Al2O3 catalysts

Fe/Al₂O₃ catalysts with different Fe loadings (10-90 mol%) were prepared by hydrothermal method. Ethanol decomposition was studied over these Fe/Al₂O₃ catalysts at temperatures between 500 and 800 °C to produce hydrogen and multi-walled carbon nanotubes (MWCNTs) at the same time. The results showed that the catalytic activity and stability of Fe/Al₂O₃ depended strongly on the Fe loading and reaction temperature. The Fe(30 mol%)/Al₂O₃ and Fe(40 mol%)/Al₂O₃ were both the effective catalyst for ethanol decomposition into hydrogen and MWCNTs at 600 °C. Several reaction pathways were proposed to explain ethanol decomposition to produce hydrogen and carbon (including nanotube) at the same time.     

Growth evolution of rapid grown aligned carbon nanotube forests without water vapor on Fe/Al2O3/SiO2/Si substrate

This paper presents the growth evolutions in terms of the structure, growth direction and density of rapid grown carbon nanotube (CNT) forests observed by scanning and transmission electron microcopies (SEM/TEM). A thermal CVD system at around 700 °C was used with a catalyst of Fe films deposited on thin alumina (Al₂O₃) supporting layers, a very fast raising time to the growth temperature below 25 °C/s, and a carbon source gas of acetylene diluted with hydrogen and nitrogen without water vapor. Activity of Fe catalyst nanoparticles was maintained for 5 min during CVD process, and it results in CNT forests with heights up to 0.6 mm. SEM images suggest that the disorder in CNT alignment at the initial stage of CNTs plays a critical role in the formation of continuous CNT growth. Also, the prolonged heating process leads to increased disorder in CNT alignment that may be due to the oxidation process occurring at the Fe nanoparticles. TEM images revealed that both double- and few-walled CNTs with diameters of 5-7 nm were obtained and the CNT density was controlled by thickness of Fe catalytic layer. The number of experiments at the same conditions showed a very good repeatability and reproducibility of rapid grown CNT forests.     

Low-Temperature Growth of Carbon Nanotubes on Bi- and Tri-metallic Catalyst Templates

Low temperature growth process of carbon nanotubes (CNTs) over bi-metallic (Co–Fe) and tri-metallic (Ni–Co–Fe) catalysts on Si/Al/Al₂O₃ substrates is carried out from acetylene precursor using hydrogen, ammonia or nitrogen as a carrier in a low pressure chemical vapor deposition system. Using the tri-metallic Ni–Co–Fe catalyst template, vertically aligned CNTs of ~700 nm length could be grown already at 450 °C within 10 min using ammonia as a carrier. Within the same period of time, on bi-metallic Co–Fe catalyst templates, ~250 nm long aligned nanotubes emerged already at 400 °C in nitrogen carrier. At low temperatures most of the catalyst materials were elevated from the support by the grown nanotubes indicating tip growth mechanism. The structure of catalyst layers and nanotube films was studied using scanning and transmission electron microscopy and atomic force microscopy.     

A crucial role of O2 and O2 on mayenite structure for biomass tar steam reforming over Ni/Ca12Al14O33

Newly synthesized nickel calcium aluminum catalysts (Ni/Ca₁₂Al₁₄O₃₃) were tested in a fixed bed reactor for biomass tar steam reforming, toluene as tar destruction model compound. Four catalysts (Ni/Ca₁₂Al₁₄O₃₃) were prepared with Ni loading amount from 1, 3, 5 to 7 wt%, even 1% loading catalyst also showed excellent performance. Catalysts aged experiments in the absence (60 h on stream) and presence of H₂S were characterized by BET, X-ray diffraction (XRD), and Raman spectra. It was observed that Ni/Ca₁₂Al₁₄O₃₃ showed excellent sustainability against coke formation due to the “free oxygen” in the catalysts. It also exhibited higher H₂S-poisoning resistance property compared to the commercial catalysts Ni/Al₂O₃ (5%) and Ni/CaO_0.5/MgO_0.5. Raman spectra revealed that “free oxygen O₂⁻ and O₂²⁻” in the structure of the catalysts could be substituted by sulfur then protected Ni poisoning on some degree, but reactivation experiments by O₂ flowing showed that the sulfide Ni/Ca₁₂Al₁₄O₃₃ was difficult to completely restore, incorporation of sulfur in the structure only partly regain by O₂. The kinetic model proposes, as generally accepted, a first-order reaction for toluene with activation energy of 82.06 kJ mol⁻¹ was coincident with the literature data. The Ni/Ca₁₂Al₁₄O₃₃ catalyst was effective and relative cheap, which may be lead to reduction in the cost of hot gas cleaning process.     

Performance of Ni catalyst supported on La-hexaaluminate in CO<Subscript>2</Subscript> reforming of CH<Subscript>4</Subscript>

CO₂ reforming of CH₄ was performed using Ni catalyst supported on La-hexaaluminate which has been an well-known material for high-temperature combustion. La-hexaaluminate was synthesized by sol-gel method at various conditions where different amount of Ni (5–20 wt%) was loaded. Ni/La-hexaaluminate experienced 72 h reaction and its catalytic activity was compared with that of Ni/Al₂O₃, Ni/La-hexaaluminate shows higher reforming activity and resistance to coke deposition compared to the Ni/Al₂O₃ model catalyst. Coke deposition increases proportionally to Ni content. Consequently, Ni(5)/La-hexaaluminate(700) is the most efficient catalyst among various Ni/La-hexaaluminate catalysts regarding the cost of Ni in Ni(X)/La-hexaaluminate catalysts. BET surface area, XRD, EA, TGA and TPO were performed for surface characterization. This work was presented at the 6 ^th Korea-China Workshop on Clean Energy Technology held at Busan, Korea, July 4–7, 2006.     

Catalysis of NiO–Al2O3 aerogels for the CO2-reforming of CHF4

Uniform and monolithic NiO–Al₂O₃ aerogels were prepared from cyclic nickel glycoxide, (CH₂O)₂Ni, and boehmite sol, AlOOH, and the catalyst performance of the aerogels for the CO₂-reforming of methane was investigated. The NiO–Al₂O₃ aerogels showed higher activity than impregnation NiO/Al₂O₃ catalysts, while the aerogels exhibited much less activity for coking than the impregnation catalysts. Less deactivation was also observed on the aerogel catalysts than on the impregnation catalysts in the continuous-flow reaction. The Ni was uniformly incorporated throughout alumina where both the metal and the support exist in the aerogel form, i.e., Ni–O–Al bond was considered to be formed in the aerogels. As a result, fine Ni particles appeared after H₂ reduction throughout the alumina support with high dispersion, which brought about not only higher activity but also much less activity for coking on the aerogels. Retardation of catalyst deactivation was ascribed to the suppression of both coking and sintering of Ni particles on the aerogels. This revised version was published online in July 2006 with corrections to the Cover Date.     

Influences of NH3 pre-treatment and radicals on the growth of carbon nanotubes

A triple-layered catalyst (Al/Fe/Mo) undergoes considerable restructuring of surface morphology during NH₃ annealing prior to carbon nanotube (CNT) growth. The diameter (or density) of Al_xO_y–Fe clusters formed during the annealing is found to be dependent on the concentration ratio of NH₃ to H₂O present inside the chamber, which is confirmed by in-situ mass spectroscopy. The different diameter clusters then affect the types of CNTs (i.e. single or multi-walled CNTs) during the growth. Here, a growth model is also presented, where hydrocarbon radicals (C₅H₉, C₆H₉, and C₆H₁₃) generated from C₂H₂ pyrolysis (~ 800 °C) can be used as effective precursors to synthesize CNTs.     

Nickel Oxide Based Supported Catalysts for the In-situ Reactions of Methanation and Desulfurization in the Removal of Sour Gases from Simulated Natural Gas

Supported nickel oxide based catalysts were prepared by wetness impregnation method for the in-situ reactions of H₂S desulfurization and CO₂ methanation from ambient temperature up to 300 °C. Fe/Co/Ni (10:30:60)–Al₂O₃ and Pr/Co/Ni (5:35:60)–Al₂O₃ catalysts were revealed as the most potential catalysts, which yielded 2.9% and 6.1% of CH₄ at reaction temperature of 300 °C, respectively. From XPS, Ni₂O₃ and Fe₃O₄ were suggested as the surface active components on the Fe/Co/Ni (10:30:60)–Al₂O₃ catalyst, while Ni₂O₃ and Co₃O₄ on the Pr/Co/Ni (5:35:60)–Al₂O₃ catalyst.     

Oxidative desulfurization of dibenzothiophene over Fe promoted Co–Mo/Al_2O_3 and Ni–Mo/Al_2O_3 catalysts using hydrogen peroxide and formic acid as oxidants

This work reports the enhancing effect of a highly cost effective and efficient metal, Fe, incorporation to Co or Ni based Mo/Al_2O_3 catalysts in the oxidative desulfurization(ODS) of dibenzothiophene(DBT) using H_2O_2 and formic acid as oxidants. The influence of operating parameters i.e. reaction time, catalyst dose, reaction temperature and oxidant amount on oxidation process was investigated. Results revealed that 99% DBT conversion was achieved at 60 °C and 150 min reaction time over Fe–Ni–Mo/Al_2O_3. Fe tremendously enhanced the ODS activity of Co or Ni based Mo/Al_2O_3 catalysts following the activity order: Fe–Ni–Mo/Al_2O_3 NFe–Co–Mo/Al_2O_3 NNi–Mo/Al_2O_3 NCo–Mo/Al_2O_3, while H_2O_2 exhibited higher oxidation activity than formic acid over all catalyst systems. Insight about the surface morphology and textural properties of fresh and spent catalysts were achieved using scanning electron microscopy(SEM), X-ray diffraction(XRD), energy dispersive X-ray(EDX)analysis, Atomic Absorption Spectroscopy(AAS) and BET surface area analysis, which helped in the interpretation of experimental data. The present study can be deemed as an effective approach on industrial level for ODS of fuel oils crediting to its high efficiency, low process/catalyst cost, safety and mild operating condition.     

Steam reforming of LPG over Ni and Rh supported on Gd-CeO2 and Al2O3: Effect of support and feed composition

The steam reforming of liquefied petroleum gas (LPG) over Ni- and Rh-based catalysts supported on Gd-CeO₂ (CGO) and Al₂O₃ was studied at 750-900 °C. The order of activity was found to be Rh/CGO > Ni/CGO ∼ Rh/Al₂O₃ > Ni/Al₂O₃; we indicated that the comparable activity of Ni/CGO to precious metal Rh/Al₂O₃ is due to the occurring of gas-solid reactions between hydrocarbons and lattice oxygen () on CGO surface along with the reaction taking place on the active site of Ni, which helps preventing the carbon deposition and promoting the steam reforming of LPG.The effects of O₂ (as oxidative steam reforming) and H₂ adding were further studied over Ni/CGO and Ni/Al₂O₃. It was found that the additional of these compounds significantly reduced the amount of carbon deposition and promoted the conversion of hydrocarbons (i.e., LPG as well as CH₄, C₂H₄ and C₂H₆ occurred from the thermal decomposition of LPG) to CO and H₂. Nevertheless, the addition of too high O₂ oppositely decreased H₂ yield due to the oxidizing of Ni particle and the possible combusting of H₂ generated from the reaction, while the addition of too high H₂ also negatively affect the catalyst activity due to the occurring of catalyst active site competition and the inhibition of gas-solid reactions between the gaseous hydrocarbon compounds and on the surface of CGO (for the case of Ni/CGO).