Carbon aerogel spheres prepared via alcohol supercritical drying

We have developed a method that would allow for the fabrication of carbon aerogel (CA) spheres. The inverse phase suspension polymerization of resorcinol and formaldehyde monomers with Na₂CO₃ as a catalyst followed by supercritical drying was explored. The effects of the chemical formulation and processing procedures and the conditions of the structures of organic and related carbon aerogels were studied. The experimental results indicated that it was easy to avoid the accumulation of polymerization heat during gelation, and easy to take out the products from the reaction container, through this fabrication method. Sol-gel microspheres with diameters ranging from about 30-1000μm could be obtained. After drying the sol-gel spheres under alcohol supercritical drying conditions, aerogel spheres with a bulk density of 0.8-1.0 g/cm³were prepared, and by subsequently pyrolyzing them, CA spheres with surface areas of 250-650 m²/g were obtained. The resultant CA spheres could be used as the electrode materials of supercapacitors. The specific capacitance of the CA spheres was as high as 215 F/g, and the equivalent series resistance at 48 Hz was about 1 Ω.     

Structural studies of oriented carbon nanotubes in alumina channels using high energy X-ray diffraction

Structural studies of multi-wall carbon nanotubes prepared by template pyrolytic carbon deposition from thermal decomposition of propylene at 800 °C inside channels of an alumina membrane have been performed using X-ray diffraction. The two-dimensional diffraction pattern of the deposited carbon nanotubes, recorded directly within the alumina template using an image plate detector, exhibits two dark arcs corresponding to the (0 0 2) graphitic reflection. The anisotropic scattering distribution indicates alignment of the nanotubes. The diffracted intensity was measured for the powdered samples after removing the alumina membrane using a point detector. A maximum scattering vector of K_max = 20 Å⁻¹ yielded the radial distribution function, providing evidence that the investigated nanotubes form a distorted hexagonal network that implies the presence of five-membered rings.     

Structure of nanoporous carbon produced from boron carbide

The structure of nanoporous carbon produced by chlorination of powdered boron carbide at 600, 800, 1000, 1300, 1500, and 1800 °C has been studied by scanning electron microscopy, X-ray diffraction analysis, helium pycnometry, and low-temperature adsorption of nitrogen. On the basis of the results obtained, suggestions are made concerning the type of organization of the nanoporous structure of these materials. The evolution of the structure of nanoporous carbon is analyzed in relation to the synthesis temperature of nanoporous carbon. It is shown that, as the chlorination temperature increases, the structure of nanoporous carbon becomes more perfect: it changes from paracrystalline to turbostratic. The specific surface area decreases from 2200 to 36 m²/g, the volume of micropores decreases from 0.93 to 0.01 cm³/g, and that of mesopores first increases from 0.15 cm³/g (600 °C) to 0.57 cm³/g (1000 °C) and then decreases to 0.19 cm³/g (1800 °C). The total pore volume decreases from 1.08 to 0.20 cm³/g.     

Selective formation of carbon nanotubes over Co-modified beta zeolite by CCVD

Multiwall carbon nanotubes containing carbon-zeolite composite materials have been obtained by ethylene catalytic chemical vapor deposition (CCVD) on Co-modified beta zeolite powder. High carbon selectivity to nanotubes was achieved. The combined physical characterisation through several techniques, such as TEM, HRTEM, SEM, XRD, N₂ adsorption-desorption, allows to determine the geometric characteristics of nanotubes and their dependence of catalyst and synthesis conditions.     

Synthesis methods for preparing microporous carbons with a structural regularity of zeolite Y

As reported in previous communications, novel porous carbons were synthesized by using zeolite Y as a template. The carbons possess a periodic ordering structure and high BET surface area with large micropore volume. In this work, the details of the synthesis methods for preparing the ordered microporous carbons were examined. It was found that the following two-step process, the filling of carbon into zeolite channels by impregnation of furfuryl alcohol and then chemical vapor deposition (CVD) of propylene, was indispensable for preparing carbon with highly periodic ordering. In addition, low-temperature CVD and the further heat treatment of zeolite/carbon composite after the CVD are key points for the appearance of both good long-range periodicity and very high BET surface area with almost no mesoporosity in the carbons.     

Carbon infiltration of carbon-fiber preforms by catalytic CVI

Experimental studies were conducted to assess catalytic chemical vapor infiltration processing for preparing carbon/carbon composites as a potential improvement to conventional one. The catalyst was introduced into the carbon fiber preforms by wet impregnation. Using C₃H₆/Ar/H₂ as the original gas, catalytic carbon was formed at 500-1000 °C for 1-3 h. It was found that carbon filaments were formed as the preparing temperatures were 500-700 °C, and carbon particles could be obtained at 800-1000 °C. The increasing rate of density was up to 0.916 g/ml/h when the sample was formed at 600 °C for 1 h with the catalytic of 0.7 wt.% Ni, and the carbon yield arrived to 90 wt.% . According to the micrographs of catalytic carbon, the forming mechanism of carbon filaments agreed with that of carbon filaments due to a metal catalyst. The weighted average interlayer spacing of C/C composites with catalytic carbon decreased to 0.341.     

Intermetallic catalyst for carbon nanotubes (CNTs) growth by thermal chemical vapor deposition method

The methane conversion and carbon yield of the chemical vapor deposition (CVD) reaction suggests that the optimum reaction conditions of the formation of multi-wall carbon nanotubes (MWCNTs) can be obtained by using a 50 mg of nano-MgNi alloy under pyrolysis of the pure CH₄ gas with the flow rate about 100-120 cm³/min at 650 °C for 30 min. Raman results indicate the CNTs are in multi-wall structure, since no single-wall characteristic features appearing in the 200-400 cm⁻¹ region. This is consistent with those of the XRD and TGA findings. Under selected condition, the carbon yield and the CNTs purity can reach up to 1231% and 92% in the presence of hydrogen. It is presumable that the presence of hydrogen in the pyrolysis of CH₄ prevents the deactivation of catalysts and enhances the graphitization degree of CNTs. In addition, the presence of Mg metal in the alloy can prevent the aggregation of the Ni metal and forms the active Mg₂Ni phase to enhance the CH₄ pyrolysis to form CNTs. After the purification procedures with both air oxidation at 550 °C and HCl treatments, the final purified yield and purity of CNT reach to 73.2% and (98.04 ± 0.2)% respectively.     

Single- and multi-wall carbon nanotubes produced using the floating catalyst method: Synthesis, purification and hydrogen up-take

The floating catalyst (FC) method for synthesis of single- and multi-wall carbon nanotubes was optimized and scaled up to yield 6 g/h and 20 g/h of products, respectively. Different CNTs purification methods were compared. It was found that the procedure involving room temperature bromination is the most effective to purify the FC-CNTs. The hydrogen up-take capacities of the different products were measured using the quasi-equilibrium volumetric method. It was shown that, at room temperature and gas pressure up to 150 atm for both SWCNTs and MWCNTs, hydrogen up-take does not exceed 1.5 wt.% and is weakly dependent on the product purity.     

Preparation of vapor-grown carbon fibers from deoiled asphalt

Vapor-grown carbon fibers (VGCFs) with high-purity have been successfully prepared from the thermal cracking of deoiled asphalt (DOA) with ferrocene as catalyst by chemical vapor deposition (CVD) in argon atmosphere and characterized systematically by field-emission scanning electron microscopy (FE-SEM), high resolution transmission electron microscopy (HRTEM) and X-ray diffraction (XRD) techniques. Results showed that VGCFs with a diameter of 150-200 nm and a maximum length of 10-40 μm can be obtained.     

Adsorption properties of carbon molecular sieves prepared from an activated carbon by pitch pyrolysis

In this study a heat-treatment process using an activated carbon and coal-tar pitch was developed to prepare carbon molecular sieves (CMSs) for CH₄/CO₂ separation. This process results in a partial blockage of the pores of the activated carbon precursor, so that a reduction in the pore size takes place. Equilibrium CO₂ adsorption measurements at different temperatures, and CO₂ and CH₄ kinetic measurements at different temperatures and feed pressures were carried out using the TEOM technique for a carbon molecular sieve (CMS) prepared by this process (sample CB3) and a commercial CMS (Takeda 3A, sampleT3A). The overall diffusion for CO₂ in sample CB3 was faster than that in T3A and a slightly higher CO₂ adsorption capacity of CB3 was obtained. The transient uptake profiles in both samples at different temperatures and different CO₂ partial pressures were described in some cases by a micropore diffusion model, and in other cases by a dual resistance model. Both equilibrium and kinetic results demonstrate a better CO₂/CH₄ separation performance for the CMS prepared in the present study (CB3) than for the commercial CMS (Takeda 3A), due to the existence of slightly wider pore-mouth openings in sample CB3. This study demonstrates that the process used in this work is an interesting and reproducible approach to prepare CMS for CO₂/CH₄ separation.     

Prediction of carbon nanotube growth success by the analysis of carbon-catalyst binary phase diagrams

The growth of carbon nanotubes (CNTs) was attempted using a vapor-phase CVD method, and a wide variety of transition metals, in the form of metallocenes and chlorides, were used as potential growth catalysts. Well-aligned mats of multi-walled carbon nanotubes were observed in samples catalyzed with iron, nickel, and cobalt. Nanotube lengths could be varied between 3 μm and 3 mm, and diameters ranged from 20 nm to 60 nm. X-ray diffraction, energy dispersive X-ray spectroscopy, and Mossbauer spectroscopy were used to determine the compositions of the nanotube products. None of the other elements studied, consisting of Cr, Mn, Zn, Cd, Ti, Zr, La, Cu, V, and Gd, were able to successfully catalyze the growth of CNTs. A study was performed of the respective metal-carbon binary phase diagrams to understand why the catalytic ability of different elements varied. Successful catalysts had carbon solubility limits of 0.5 wt.% to 1.5 wt.% carbon, followed closely by nanotube growth through graphite precipitation. Unsuccessful catalysts were found to have either nearly zero carbon solubility, or to form numerous intermediate carbides, making it difficult for the diffusion required for graphite precipitation to occur. These findings were then used to look for other potential CNT catalysts by examining the phase diagrams of a wide variety of metals.     

Controlling the diameter distribution of carbon nanotubes grown from camphor on a zeolite support

Single-wall and multi-wall carbon nanotubes (SWNTs and MWNTs, respectively) of controlled diameter distribution were selectively grown by thermal decomposition of a botanical hydrocarbon, camphor, on a high-silica zeolite support impregnated with Fe-Co catalyst. Effects of catalyst concentration, growth temperature and camphor vapor pressure were investigated in wide ranges, and diameter distribution statistics of as-grown nanotubes was analyzed. High yields of metal-free MWNTs of fairly uniform diameter (∼10 nm) were grown at 600-700 °C, whereas significant amounts (∼30%) of SWNTs were formed at 850-900 °C within a narrow diameter range of 0.86-1.23 nm. Transmission electron microscopy and micro-Raman spectroscopy reveal that camphor-grown nanotubes are highly graphitized as compared to those grown from conventional CNT precursors used in chemical vapor deposition.     

Single-walled carbon nanotube growth using cobalt nanoparticles prepared by vacuum deposition on a surface-active liquid

We demonstrate that the Co nanoparticles prepared by vacuum deposition on a surface-active liquid can be used as catalysts of single-walled carbon nanotube (SWCNT) growth using alcohol catalytic chemical vapor deposition method. These Co nanoparticles are embedded in the y-type zeolite powder. The Co nanoparticles used in this study is the highly efficient catalysts for CNT growth, which is comparable to the commonly-used Co-Fe binary metal catalysts embedded in the y-type zeolite. The preparation method of the metal nanoparticles used in this study is very simple. Thus, such metal nanoparticles might be promising as catalysts of CNT growth.     

Carbon/carbon composites prepared by chemical vapour deposition

This paper summarizes the results of the authors' work on composites prepared by chemical vapour deposition (CVD), using propylene as a source of carbon and various substrates (cellulose carbon, natural graphite, different grades of carbon fibres bonded by phenolic or CVD carbon). The equations relating

1. (i) open porosity P with infiltration rate (− dP/dt = kP).

2. (ii) apparent density of the composites d_app with P (d_app = nP + q).

3. (iii) composite properties Y with d_app (Y = ad_app^b) have been confirmed for the systems studied up to the highest composite densities attained. The constants k, n, q, a and b vary with infiltration conditions, nature of the substrate (involving bonding carbon in the skeleton), heat treatment (HT) conditions and geometrical factors.

For a given set of conditions, infiltration rate increases with temperature and the partial pressure of propylene, but decreases with residence time. Contrary to the composite properties, the kinetics of infiltration are not influenced by the nature of the substrate, except for the initial stage before the substrate is coated by the CVD carbon, but depends on the shape and size of open pores. The influence of the nature of the carbon used to bond the fibres may be of particular importance for composite properties, the latter being also influenced by the state of the surface of the fibres. Among the geometrical factors, the studied effect of fibre content has been found to strongly influence the infiltration rate, in agreement with predictions, as well as the composite properties. The influence of HT on composite properties can be explained by the resulting structural changes in the substrate and the matrix and by the effect of stress relaxation.

Mechanism of carbon nanotube growth from camphor and camphor analogs by chemical vapor deposition

Single walled nanotubes have been synthesized by chemical vapor deposition from camphor, camphor analogs (camphorquinone, norcamphor, norbornane, camphene, fenchone), and various other precursors (menthone, 2-decanone, benzene, methane). The high temperature conditions (865 °C) and Fe/Mo alumina catalyst used in the syntheses are archetypal conditions for the production of single walled carbon nanotubes. It has been shown that the mechanism of tube growth is unlikely to depend upon the production of reactive five- and six-member rings, as has been previously suggested. The results suggest that the presence of oxygen in the precursor does not significantly improve the quality of tubes by etching amorphous carbon: it is suggested that the control of the flux of the precursor to the catalyst is more important in the production of high quality tubes. There is, however, evidence for different distributions of tube diameter being produced from different precursors.     

Carbon foams prepared from polyimide using urethane foam template

Polyimide and carbon foams were successfully prepared using polyurethane foams as a template. Impregnation of polyimide precursor, poly(amide acid), followed by imidization at 200 °C gave polyurethane/polyimide (PU/PI) composite foams, which resulted in PI foams by heating above 400 °C and then carbon foams above 800 °C. Foams carbonized at 1000 °C were graphitized by the heat treatment at 3000 °C, keeping foam characteristics. Two applications of these carbon foams, i.e., an adsorbent of ambient water vapor and a substrate of photocatalyst anatase TiO₂, were experimentally confirmed. For the former application, the present foam could be characterized by prompt adsorption of ambient water vapor. Some of carbon foams prepared were floating on water, even after loading photocatalyst anatase, which might be advantageous for photodecomposition of pollutants in water in respect to the UV rays efficiency.     

Carbon nanostructures produced by CCVD with induction heating

The catalytic chemical vapor deposition (CCVD) method in which the outer furnace is replaced by the high frequency induction heating (IH) has been used for synthesis of carbon nanostructures. Using different catalysts, various types of carbon nanofibers were obtained, with the absence of the catalyst particles at their tip as a common characteristic. The IH mode combined with the CCVD method seems attractive for the synthesis of carbon nanostructures, allowing a significant decrease of energy consumption and of the overall reaction time as compared with the heating mode with outer furnace.