Growth kinetics of MWCNTs synthesized by a continuous-feed CVD method

Unlike two-step chemical vapor deposition (CVD) methods using pre-deposited catalyst particles, in a continuous-feed CVD process, the liquid feed (consisting of catalytic precursor and hydrocarbon source) is continuously supplied into the reactor causing catalyst particle formation, nucleation of carbon nanotubes (CNTs) and CNT growth to occur simultaneously throughout the reaction period. In order to observe these processes, CVD experiments were conducted for different durations (30 s to 3 h) and the product multiwalled carbon nanotubes (MWCNTs) were characterized using scanning electron microscopy. It was found that the nanotubes did not grow in the vapor phase and that substrates played an important role in the growth by providing a place for them to anchor before growth took place. Based on transmission electron microscopy images, it has been suggested that MWCNTs grew by root-growth mechanism from the catalyst particles that were deposited on the substrate during the early stages. At long process times, continuously supplied feed gas produced additional catalyst particles which were deposited mostly on the growing nanotube mat. Due to weak catalyst-mat interaction, the additional nanotubes grew by tip growth. A comprehensive MWCNT growth model has been presented for the continuous-feed CVD.     

Platelet-like catalyst design for high yield production of multi-walled carbon nanotubes by catalytic chemical vapor deposition

We investigated the effect of catalyst design on the synthesis of multi-walled carbon nanotubes (MWCNTs) by chemical vapor deposition (CVD). A set of highly active supported sol–gel Co–Mo/MgO and Ni–Mo/MgO catalysts was prepared systematically modifying the calcination temperature. First, the evolution of catalysts’ crystallographic phases and their morphology were studied by X-ray diffraction (XRD), Raman spectroscopy, scanning electron (SEM) and transmission electron (TEM) microscopy. Second, the catalysts were used for the CVD growth of MWCNTs. The resulting materials were analysed by SEM and TEM, Raman and XRD to establish a relation between catalyst design and MWCNT yield. We show that our catalyst synthesis route leads to the formation of laminar non-porous catalyst systems, which at a calcination temperature of 800 °C stabilize in a crystallographic phase of Me_xMg_1−xMoO₄ (Me = Co or Ni). We give evidence that increased MWCNT yields of more than 3000 wt.% with respect to the catalysts are directly related to the aforementioned crystallographic phase. Finally, we propose a growth model based on the continuous exfoliation of platelet-like catalyst systems. This consistently explains the high catalytic activity towards MWCNT production using a non-porous catalyst. Our findings provide important insights for catalyst design strategies towards large-scale MWCNT production.     

Self-assembling of multi-walled carbon nanotubes on a porous carbon surface by catalyst-free chemical vapor deposition

Synthesis of carbon nanotubes (CNTs) by catalyst-free chemical vapor deposition (CFCVD) is one of the most important challenges in nanotube science. Self-assembling multi-walled CNTs (MWCNTs) were produced on a porous carbon surface using carbon black (CB) as a substrate, at 800 °C by the decomposition of diluted ethylene. MWCNTs with an outer-diameter distribution of 20–80 nm, examined by scanning and transmission electron microscopy, could be self-assembled on pore structures of CB surface by CFCVD.     

Narrow multi-walled carbon nanotubes produced by chemical vapor deposition using graphene layer encapsulated catalytic metal particles

The use of graphene layer encapsulated catalytic metal particles for the growth of narrower multi-walled carbon nanotubes (MWCNTs) has been studied using plasma-enhanced chemical vapor deposition and conventional thermal CVD. Ni–C or Fe–C composite nanoclusters were fabricated using the dc arc discharge technique with metal–graphite composite electrodes carrying a current of 100–200 A in a stainless-steel chamber filled with He and CH₄ mixture gas at 27 kPa. Nano-sized grains with diameters less than 10 nm were fabricated and deposited on a Si substrate, and were used as a catalyst for MWCNT growth. Structural analyses of the composite nanoclusters and MWCNTs were carried out using transmission electron microscopy. The results show that the diameters of the MWCNTs were reduced from 50–100 nm for a conventional Ni thin film-evaporated Si substrate to a minimum of roughly 2–4 nm in the present study.     

Optimization of methane cold wall chemical vapor deposition for the production of single walled carbon nanotubes and devices

Carbon nanotubes are synthesized by cold wall chemical vapor deposition (CVD) using methane as the carbon source and iron thin film catalyst. The yield of thin nanotubes as determined by scanning electron microscopy (SEM) is strongly dependent on the precise CVD process and the preparation of the substrate. The effects of pressure (5–80 kPa), temperature (700–950 °C), substrate conditioning (air preheat) and metallization (Fe, Al, Mo) on thin nanotube yield are reported. High yields of thin nanotubes are obtained under optimum conditions. These thin nanotubes are candidates to be single walled carbon nanotubes (SWNTs) and Raman spectroscopy, photoluminescence spectroscopy and electrical transport provide evidence that, at least at optimum conditions, many, and perhaps all of the thin nanotubes are single walled. Single nanotube field effect transistors are fabricated and factors affecting device yield are reported. Optimum single nanotube device yield does not necessarily coincide with the optimum nanotube yield.     

Effect of annealing temperature on wettability of TiO2 nanotube array films

Highly ordered TiO₂ nanotube array (TN) films were prepared by anodization of titanium foil in a mixed electrolyte solution of glycerin and NH₄F and then annealed at 200°C, 400°C, 600°C, and 800°C, respectively. The samples were characterized by X-ray diffraction (XRD), scanning electron microscopy (SEM), water contact angle (WCA), and photoluminescence (PL). It was found that low temperature (below 600°C) has no significant influence on surface morphology, but the diameter of the nanotube increases from 40 to 50 nm with increasing temperature. At 800°C, the nanotube arrays are completely destroyed and only dense rutile film is observed. Samples unannealed and annealed at 200°C are amorphous. At 400°C, anatase phase appears. At 600°C, rutile phase appears. At 800°C, anatase phase changes into rutile phase completely. The wettability of the TN films shows that the WCAs for all samples freshly annealed at different temperatures are about 0°. After the annealed samples have been stored in air for 1 month, the WCAs increase to 130°, 133°, 135°, 141°, and 77°, respectively. Upon ultraviolet (UV) irradiation, they exhibit a significant transition from hydrophobicity to hydrophilicity. Especially, samples unannealed and annealed at 400°C show high photoinduced hydrophilicity.     

Growth of few-wall carbon nanotubes with narrow diameter distribution over Fe-Mo-MgO catalyst by methane/acetylene catalytic decomposition

Few-wall carbon nanotubes were synthesized by methane/acetylene decomposition over bimetallic Fe-Mo catalyst with MgO (1:8:40) support at the temperature of 900°C. No calcinations and reduction pretreatments were applied to the catalytic powder. The transmission electron microscopy investigation showed that the synthesized carbon nanotubes [CNTs] have high purity and narrow diameter distribution. Raman spectrum showed that the ratio of G to D band line intensities of I_G/I_D is approximately 10, and the peaks in the low frequency range were attributed to the radial breathing mode corresponding to the nanotubes of small diameters. Thermogravimetric analysis data indicated no amorphous carbon phases. Experiments conducted at higher gas pressures showed the increase of CNT yield up to 83%. Mössbauer spectroscopy, magnetization measurements, X-ray diffraction, high-resolution transmission electron microscopy, and electron diffraction were employed to evaluate the nature of catalyst particles.     

Direct synthesis of carbon nanofibers from South African coal fly ash

Carbon nanofibers (CNFs), cylindrical nanostructures containing graphene, were synthesized directly from South African fly ash (a waste product formed during the combustion of coal). The CNFs (as well as other carbonaceous materials like carbon nanotubes (CNTs)) were produced by the catalytic chemical vapour deposition method (CCVD) in the presence of acetylene gas at temperatures ranging from 400°C to 700°C. The fly ash and its carbonaceous products were characterized by transmission electron microscopy (TEM), thermogravimetric analysis (TGA), laser Raman spectroscopy and Brunauer-Emmett-Teller (BET) surface area measurements. It was observed that as-received fly ash was capable of producing CNFs in high yield by CCVD, starting at a relatively low temperature of 400°C. Laser Raman spectra and TGA thermograms showed that the carbonaceous products which formed were mostly disordered. Small bundles of CNTs and CNFs observed by TEM and energy-dispersive spectroscopy (EDS) showed that the catalyst most likely responsible for CNF formation was iron in the form of cementite; X-ray diffraction (XRD) and Mössbauer spectroscopy confirmed these findings.     

Highly active nitrogen-doped few-layer graphene/carbon nanotube composite electrocatalyst for oxygen reduction reaction in alkaline media

In this work the electrocatalysis of oxygen reduction on nitrogen-doped few-layer graphene/multi-walled carbon nanotube (FLG/MWCNT) composite catalyst has been investigated. These composite materials were prepared from different nitrogen precursors, acid-treated MWCNTs and graphene oxide (GO), which was synthesised from graphite by the modified Hummers’ method. Urea and dicyandiamide were used as nitrogen precursors and the doping was achieved by pyrolysing the mixture of GO and MWCNTs in the presence of these nitrogen-containing compounds at 800 °C. The N-doped composite catalyst samples were characterised by scanning electron microscopy, transmission electron microscopy and X-ray photoelectron spectroscopy, the latter method revealed successful nitrogen doping. The oxygen reduction reaction (ORR) was studied in 0.1 M KOH on glassy carbon electrodes modified with N-doped FLG/MWCNT electrocatalysts employing the rotating disk electrode (RDE) method. The RDE results indicated that these metal-free nitrogen-doped nanocarbon catalysts possess remarkable electrocatalytic activity towards the ORR in alkaline media similar to that of commercial Pt/C catalyst. The results obtained in this work are particularly important for the development of non-Pt cathode catalysts for alkaline membrane fuel cells.     

Chemical vapor-deposited carbon nanofibers on carbon fabric for supercapacitor electrode applications

Entangled carbon nanofibers (CNFs) were synthesized on a flexible carbon fabric (CF) via water-assisted chemical vapor deposition at 800°C at atmospheric pressure utilizing iron (Fe) nanoparticles as catalysts, ethylene (C₂H₄) as the precursor gas, and argon (Ar) and hydrogen (H₂) as the carrier gases. Scanning electron microscopy, transmission electron microscopy, and electron dispersive spectroscopy were employed to characterize the morphology and structure of the CNFs. It has been found that the catalyst (Fe) thickness affected the morphology of the CNFs on the CF, resulting in different capacitive behaviors of the CNF/CF electrodes. Two different Fe thicknesses (5 and 10 nm) were studied. The capacitance behaviors of the CNF/CF electrodes were evaluated by cyclic voltammetry measurements. The highest specific capacitance, approximately 140 F g⁻¹, has been obtained in the electrode grown with the 5-nm thickness of Fe. Samples with both Fe thicknesses showed good cycling performance over 2,000 cycles.     

Synthesis of multi-walled carbon nanotubes on ‘red mud’ catalysts

Red mud, a toxic waste product from bauxite processing, was used as a catalyst for the synthesis of multi-walled carbon nanotubes (MWCNTs) by fluidised bed chemical vapour deposition. The products were analysed using thermogravimetric analysis, Raman spectroscopy, and transmission electron microscopy. Using ethylene at 650 °C a MWCNT yield of 375% (with respect to Fe loading) was obtained. Carbon products were approximately 75% MWCNTs with an I_G/I_D ratio from Raman spectroscopy of 1.43. The production technique and reaction conditions used are conducive to large-scale CNT production, offering a potential value-added commercial use for red mud.     

The formation mechanisms of multi-wall carbon nanotubes over the Ni modified MCM-41 catalysts

Multi-wall carbon nanotubes (MWCNTs) were grown by thermal chemical vapor deposition (thermal CVD) of CH₄ by using Ni-MCM-41 as the catalyst. Methane pyrolysis has been performed in a quartz tube reactor over the catalyst surface to form carbon atoms via dehydrogenation process. The migration and rearrangement of the surface carbon atoms result in the formation of MWCNTs. Transmission electron microscope (TEM) and scanning electron microscope (SEM) were used to determine the morphologies and structures of CNTs, and Raman spectroscopy was exploited to analyze their purity with the relative intensity between the D-band (Disorder band) in the vicinity of 1,350 cm⁻¹ which is characteristic of the sp³ structure and G-band (Graphitic band) in vicinity of 1,580 cm⁻¹ which is characteristic of the sp² structure. In addition, the controlling factors of methane pyrolysis such as the catalyst composition; the reaction temperature, and the methane flow rate on the formation of MWCNTs were investigated to optimize the structure and yield of MWCNTs. SEM/TEM results indicate that the yield of the CNTs increases with increasing Ni concentration in the catalyst. The optimized reaction temperature to grow CNT is located between 640 and 670 °C. The uniform and narrow diameter MWCNTs form at lower flow rate of methane (∼30 sccm), and non-uniform in diameter and disorder structure of MWCNTs are observed at higher flow rate of methane. This is consistent with Raman analysis that the relative intensity of I _D/I _G increases with increasing methane flow rate. The formation mechanisms of the MWCNTs on the Ni-MCM-41 catalyst have been determined to be a Tip-Growth mode with a nanoscale catalyst particle capsulated in the tip of the CNT.     

The effect of growth temperature and iron precursor on the synthesis of high purity carbon nanotubes

Aligned multiwalled carbon nanotubes (MWCNTs) of high purity, low metal content and narrow size distribution were synthesized by chemical vapour deposition of acetylene along with iron-organometallic compounds in the temperature range 650–850 °C. The obtained MWCNTs were characterized by thermogravimetric analysis, scanning electron microscopy, transmission electron microscopy and N₂ adsorption. The effect on the carbon nanotube structure of different parameters such as, reaction temperature, nature of the iron catalyst precursor, the reaction mixture flow rate and the relative proportion of metal precursor to carbon source, has been studied. It was found that the outer and inner diameters of the carbon nanotubes were directly proportional to the iron catalyst concentration. Moreover, the wall numbers and the diameters of the carbon nanotubes were related to their apparent specific surface areas.     

Effective adhesion of Pt nanoparticles on thiolated multi-walled carbon nanotubes and their use for fabricating electrocatalysts

Multi-walled carbon nanotubes (MWCNTs) were functionalized via π − π interaction with benzyl mercaptan. The subsequent bonding of thiol groups with Pt offered strong adhesion of Pt nanoparticles on MWCNT surface. Thermal treatment was introduced as the essential step of the catalyst preparation. The structure and morphology of the resulting Pt/MWCNT composite were characterized by transmission electron microscopy and X-ray diffraction, the results show that Pt nanoparticles were highly dispersed and effectively adhered on MWCNTs. The excellent electrocatalytic activity of the Pt/MWCNT composite for the oxidation of methanol was demonstrated by cyclic voltammetry.     

Synthesis of carbon nanotubes filled with Fe3C nanowires by CVD with titanate modified palygorskite as catalyst

Multi-walled carbon nanotubes (MWCNTs) have been successfully synthesized with titanate-modified palygorskite as catalyst and acetylene as carbon source by chemical vapor deposition (CVD) at high temperature. Transmission electron microscopy (TEM) studies showed that there were a lot of carbon nanotubes partially filled with elongated foreign material in their inner cavities. X-ray energy dispersive spectrum (EDS) analyses and selected area electron diffraction (SAED) investigations on the encapsulated material revealed that it was single crystalline iron carbide (Fe₃C) derived from ferric precursors in the mineral. The yield of carbon nanotubes was influenced by preparation temperature based on thermal gravimetric analyses (TGA). The relative quantity of Fe₃C nanowires was influenced by the temperature and the local structure of nanotubes upon TEM observations. A growth mechanism is also proposed in the paper.     

Synthesis of carbon nanotubes by pyrolysis of solid Ni(dmg)2

We describe the high yield synthesis of multi-walled carbon nanotubes (MWCNTs) and the determination of the optimum production conditions. The method involves the catalytic pyrolysis of solid Ni(dmg)₂ under an Ar atmosphere. The obtained materials were characterized by scanning electron microscopy (SEM), energy dispersive X-ray (EDX) analysis, high resolution transmission electron microscopy (HRTEM), X-ray diffraction (XRD), Raman spectroscopy and thermogravimetry analysis (TGA). The data revealed the formation of MWCNTs surrounded by a varying quantity of byproducts such as amorphous carbon and metallic particles, depending mainly on the reaction temperature. Pyrolysis of Ni(dmg)₂ at 900 °C results in the production of nanotube material with the highest degree of crystallinity.     

A comparative study of alcohols and ketones as carbon precursor for multi-walled carbon nanotube growth

A comparative study of the growth of multi-walled carbon nanotubes (MWCNTs) from the vapors of methanal, 2-propanone, ethanol, 2-butanone, and 2-propanol was carried out aiming at detecting the role of the carbon source in the quality of the nanotubes. The growth was carried out with a catalyst mixture of Mn and Co salts impregnated in zeolite powder, using a fixed-bed reactor under atmospheric pressure at a temperature of 600 °C. The samples were characterized by High-resolution transmission electron microscopy, scanning electron microscopy, Raman spectroscopy, and thermal analysis. Both the presence of amorphous carbon in the raw sample and the structural characteristics of the MWCNTs depend on the kind of solvent employed in the growth. The role of CH₃ and OH radicals in the MWCNT obtained in this work was determined. Acetone (2-propanone) was found to be the best solvent for the preparation of MWCNTs.     

Polypropylene as a carbon source for the synthesis of multi-walled carbon nanotubes via catalytic combustion

Multi-walled carbon nanotubes (MWCNTs) were efficiently synthesized by catalytic combustion of polypropylene (PP) using nickel compounds (such as Ni₂O₃, NiO, Ni(OH)₂ and NiCO₃ · 2Ni(OH)₂) as catalysts in the presence of organic-modified montmorillonite (OMMT) at 630-830 °C. Morphologies of the sample undergoing different combustion times were observed to investigate actual process producing MWCNTs by this method. The obtained MWCNTs were characterized by X-ray diffraction (XRD), transmission electron microscope and Raman spectroscopy. The yield of MWCNTs was affected by the composition of PP mixtures with OMMT and nickel compounds and the combustion temperature. The proton acidic sites from the degraded OMMT layers due to the Hoffman reaction of the modifiers at high temperature played an important role in the catalytic degradation of PP to supply carbon sources that are easy to be catalyzed by nickel catalyst for the growth of MWCNTs. The XRD measurements demonstrated that the nickel compounds were in situ reduced into the Ni(0) state with the aid of hydrogen gas and/or hydrocarbons in the degradation products of PP, and the Ni(0) was really the active site for the growth of MWCNTs. The combination of nickel compounds with OMMT was a key factor to efficiently synthesize MWCNTs via catalytic combustion of PP.     

Lithographically defined site-selective growth of Fe filled multi-walled carbon nanotubes using a modified photoresist

Partially Fe filled multi-walled carbon nanotubes (MWCNTs) were grown by chemical vapor deposition with propane at 850 °C using a simple mixture of iron (III) acetylacetonate (Fe(acac)₃) powder and conventional photoresist. Scanning electron microscopy revealed that catalytic nanoparticles with an average diameter of 70 nm are formed on the Si substrate which governs the diameter of the MWCNTs. Transmission electron microscopy shows that the nanotubes have a multi-walled structure with partial Fe filling. A site-selective growth of partially Fe filled MWCNTs is achieved by a simple photolithographic route.