Inhibition of catalytic oxidation of carbon/carbon composites by boron-doping

The inhibition effect of high temperature boron-doping on the catalytic oxidation of carbon/carbon composites was investigated. Boron-doping at 2500 °C was found to improve the oxidation resistance of catalyst-loaded composites. Evident inhibition mechanisms include the reduction of active site number by increasing the crystallite size and the site blockage by formed boron oxide. Boron-doping at less than 1.0 wt.% was found to almost completely suppress the catalytic effect of calcium acetate after a slight carbon conversion. This inhibition effect was much less significant in the case of potassium-catalyzed oxidation where only a slight inhibition effect was observed. This is believed to be the essential result of the unique properties of potassium catalyst. Due to its wetting ability and mobility, potassium catalyst could form and maintain good interfacial contact with any exposed carbon surface regions.     

Ultrafine SnO2 dispersed carbon matrix composites derived by a sol-gel method as anode materials for lithium ion batteries

Ultrafine crystalline SnO₂ particles (2-3 nm) dispersed carbon matrix composites are prepared by a sol-gel method. Citric acid and hydrous SnCl₄ are used as the starting constituents. The effect of the calcination temperatures on the structure and electrochemical properties of the composites has been studied. Structure analyses show that ultrafine SnO₂ particles form and disperse in the disordered carbon matrix in the calcination temperature range of 500-800 °C, forming SnO₂/C composites, and the carbon content shows only a slight increase from 35.8 wt.% to 39.1 wt.% with the temperature. Nano-Sn particles form when the calcination temperature is increased to 900 °C, forming a SnO₂/Sn/C composite, and the carbon content is increased to 49.3 wt.%. Electrochemical testing shows that the composite anodes provide high reversible cycle stability after several initial cycles, maintaining capacities of 380-400 mAh g⁻¹ beyond 70 cycles for the calcination temperature of 600-800 °C. The effect of the structure feature of the ultrafine size of SnO₂ and the disordered carbon matrix on the lithium insertion and extraction process, especially on the reversible behavior of the lithium ion reaction during cycling, is discussed.     

Si-C-O glass-like compound/exfoliated graphite composites for negative electrode of lithium ion battery

Two low molecular weight silicone compounds, a cyclic type having vinyl groups and a chain-type having Si-H bonds, a catalyst for curing, and a catalyst regulator were mixed. The mixture was impregnated into exfoliated graphite (EG) by sorption, and cured in air at 200 °C. By this process cross-linked silicone coatings were formed on graphite flakes. The composites of Si-C-O glass-like compounds and EG were synthesized by heat treatment of this precursor at 1000-1400 °C for 1 h in argon. The composites formed at 1000-1300 °C were amorphous by XRD and had practically the same chemical composition: Si 44-45, C 27-29, O 25-26, H < 0.5, all in mass%. The ²⁹Si MAS-NMR spectra indicated that the compound formed at 1000 °C was mainly composed of siloxane bonds and amorphous silica, whereas in the compound formed at 1300°C, Si-C bonds and amorphous silica were predominant. The insertion/extraction characteristics of lithium ions for the electrode prepared with composite:poly(vinylidene fluoride) = 90:10 mass% were examined in 1 mol L⁻¹ LiClO₄ solution of ethylene carbonate:diethyl carbonate = 50:50 vol%. High, 650-700 mA h g⁻¹, capacities and steady cycle performance at 50 mA g⁻¹ were achieved with the composites formed at 1250-1300 °C. Capacities of the composites formed at 1200 °C and lower were initially higher but decreased with increasing number of cycles. The composites formed at 1350 °C showed good cycle performance but the capacity was about 500 mA h g⁻¹ due to the formation of β-SiC. Except for the first cycle, the capacity-potential characteristics were similar to those of hard carbons and the coulomb efficiency was 95-100%. For all the composites the capacity was larger than that of graphite (372 mA h g⁻¹) in the range of 50-200 mA g⁻¹. Due to the large insertion capacity of the first cycle, the efficiency was low (60-70%) at first. By short-circuiting the working electrode to the lithium foil counter electrode for a certain period, the irreversible capacity of the first cycle was almost eliminated. It indicates that direct doping of lithium ions into composites is a promising way to increase the efficiency of the first cycle.     

Microstructures and mechanical properties of carbon/carbon composites reinforced with carbon nanofibers/nanotubes produced in situ

Using ferrocene as catalyst and toluene as the liquid precursor, carbon/carbon (C/C) composites were prepared by chemical liquid-vapor infiltration at 850-1100 °C. The microstructures and properties of C/C composites obtained with different ferrocene contents were studied. The results show smooth laminar and isotropic pyrocarbon are obtained after adding ferrocene to the precursor. Carbon nanofibers can be formed as the catalyst content is 0.3-1 wt.%. When the ferrocene content is 2 wt.%, multi-walled carbon nanotubes with the diameter about 20-90 nm are obtained together with carbon-encapsulated iron nanoparticles. After adding ferrocene to the precursor, the fracture modes of the composites change from brittle facture to tough fracture. The flexural strength of the composites is a maximum for 0.3 wt.% ferrocene in the precursor, higher than for ferrocene contents of 0, 0.5, 1 and 2 wt.%. The flexural modulus of the composites decreases after adding ferrocene to the precursor.     

Titanium-doped alumina for catalytic dehydration of methanol to dimethyl ether at relatively low temperatures

Mesoporous Al-Ti oxide composites with molar %Ti of 3, 5, 10, and 20 as well as pure γ-alumina were prepared using a template-free sol-gel method in the absence of a catalyst. The prepared composites were characterized by powder XRD, FTIR spectroscopy and N₂ adsorption for BET surface area and porosity measurements. The composites and the pure alumina possessed relatively high surface areas, 350-410 m²/g, and high porosities after calcination at 500 °C. FTIR spectroscopy was employed to study the products of the catalytic dehydration of methanol to dimethyl ether, DME, over the prepared catalysts at reaction temperatures between 180 and 300 °C. Compared with pure γ-alumina, the Ti-modified alumina with %Ti < 10 showed higher catalytic activity in the methanol dehydration and better selectivity to DME. Composites with %Ti of 3 and 5 showed the highest activity at relatively lower temperatures than the other catalysts where they showed their highest activity at 190 and 200 °C, respectively. The activity of all studied catalysts slightly decreased as the temperature was raised to 300 °C and dropped considerably when the temperature was decreased to 180 °C. However, the activity of Al-Ti-3 dropped only slightly at both temperatures. The selectivity to DME was dependent on the reaction temperature where 100% DME selectivity was obtained at temperatures ?220 °C and as the temperature was raised to 300 °C, some CH₄ and CO₂ formed on the account of DME.     

Generation of carbon nanofilaments on carbon fibers at 550 °C

Employing a relatively new method, in which carbon structures are grown from fuel rich combustion mixtures using palladium particles as catalyst, multi-scale diameter nanometer - micrometer filament structures were grown from ethylene/oxygen mixtures at 550 °C on commercial PAN micrometer carbon fibers. The filaments formed had a diameter roughly equal to the palladium particle size. At sufficiently high metal loadings (>0.05 wt.%) a bimodal catalyst size distribution formed, hence a bimodal filament size distribution was generated. Relative short, densely spaced nanofilaments (ca. 10 nm diameter), and a slightly less dense layer of larger (ca. 100 nm diameter) faster growing fibers (ca. 10 μm/h) were found to exist together to create a unique multi-scale structure. A protocol was developed such that only nano-scale fibers or a mixture of nano and sub-micron fibers could be produced. No large range order was evident in the filaments. This work demonstrates a unique ability to create a truly ’multi-scale’ carbon structure on the surface of carbon fibers. This fiber structure potentially can enhance composite material strength, ductility and energy absorption characteristics.     

Oxidation resistance of a gradient self-healing coating for carbon/carbon composites

A gradient self-healing coating consisting of three layers, SiC-B₄C/SiC/SiO₂, was examined as a multilayer protection for carbon/carbon composites. The inner layer was made of B₄C and β-SiC, the middle layer was a SiC based layer, and the outer layer was SiO₂ as an airproof layer. Both inner and middle layers were produced to be diphase structure by a pack cementation technique, and the outer airproof layer was prepared by hydrolyzing tetraethylorthosilicate. SEM and EDS investigations showed that the coating had a compositional gradient between B₄C and SiC. The coating showed great self-healing properties from 500 °C to 1500 °C. The weight loss rate of the coated composites was less than 1.3% after 50 h at 1500 °C, and coating represented excellent thermal shock resistance at 1500 °C. The oxidation kinetics of coated carbon/carbon composites showed that the Arrhenius curve consisted of three parts with two broken points at about 700 °C and 1100 °C, and the three parts corresponded to three different self-healing mechanisms in different temperature regions.     

The effect of the cobalt loading on the growth of single wall carbon nanotubes by CO disproportionation on Co-MCM-41 catalysts

Highly ordered MCM-41 mesoporous molecular sieves in which silicon was isomorphously substituted with 0.5-4 wt.% cobalt were synthesized using an alkyl template with a 16 carbon atoms alkyl chain length. These materials were used as catalysts for the synthesis of uniform diameter single wall carbon nanotubes (SWNT) by CO disproportionation (Boudouard reaction). The SWNT synthesis conditions were identical for all Co-MCM-41 samples, and consisted of pre-reduction of the Co-MCM-41 catalyst in hydrogen at 500 °C for 30 min followed by reaction with pure CO at 800 °C and 6 atm for 1 h (conditions previously optimized for 1 wt.% Co-MCM-41). The SWNT grown in the Co-MCM-41 catalysts were characterized by TGA, multi-excitation energy Raman spectroscopy and TEM. The state of the catalyst and the size of the metallic cobalt clusters formed in Co-MCM-41 during the SWNT synthesis were characterized by X-ray absorption spectroscopy. The mechanism controlling the diameter distribution of the SWNT produced is related to the size uniformity of the cobalt clusters nucleated in the Co-MCM-41 catalytic template: the SWNT growth selectivity and size uniformity is influenced by the cobalt concentration in the framework. If the cobalt is not initially strongly stabilized in the MCM-41 framework during template synthesis, the catalyst produces SWNT with a wider diameter distribution. Co-MCM-41 catalysts with up to 3 wt.% cobalt can be used to grow SWNT with a diameter distribution similar to that obtained with 1 wt.% Co-MCM-41, but at yields greater by a factor of approximately 2.4.     

Catalytic oxidative desulfurization of diesel utilizing hydrogen peroxide and functionalized-activated carbon in a biphasic diesel-acetonitrile system

This paper presents the development of granular functionalized-activated carbon as catalysts in the catalytic oxidative desulfurization (Cat-ODS) of commercial Malaysian diesel using hydrogen peroxide as oxidant. Granular functionalized-activated carbon was prepared from oil palm shell using phosphoric acid activation method and carbonized at 500 °C and 700 °C for 1 h. The activated carbons were characterized using various analytical techniques to study the chemistry underlying the preparation and calcination treatment. Nitrogen adsorption/desorption isotherms exhibited the characteristic of microporous structure with some contribution of mesopore property. The Fourier Transform Infrared Spectroscopy results showed that higher activation temperature leads to fewer surface functional groups due to thermal decomposition. Micrograph from Field Emission Scanning Electron Microscope showed that activation at 700 °C creates orderly and well developed pores. Furthermore, X-ray Diffraction patterns revealed that pyrolysis has converted crystalline cellulose structure of oil palm shell to amorphous carbon structure. The influence of the reaction temperature, the oxidation duration, the solvent, and the oxidant/sulfur molar ratio were examined. The rates of the catalytic oxidative desulfurization reaction were found to increase with the temperature, and H₂O₂/S molar ratio. Under the best operating condition for the catalytic oxidative desulfurization: temperature 50 °C, atmospheric pressure, 0.5 g activated carbon, 3 mol ratio of hydrogen peroxide to sulfur, 2 mol ratio of acetic acid to sulfur, 3 oxidation cycles with 1 h for each cycle using acetonitrile as extraction solvent, the sulfur content in diesel was reduced from 2189 ppm to 190 ppm with 91.3% of total sulfur removed.     

Electrochemical behaviour of propane-fed solid oxide fuel cells based on low Ni content anode catalysts

Two different low Ni content (10 wt.%) anode catalysts were investigated for intermediate temperature (800 °C) operation in solid oxide fuel cells fed with dry propane. Both catalysts were prepared by the impregnation of a Ni-precursor on different oxide supports, i.e. gadolinia doped ceria (CGO) and La_0.6Sr_0.4Fe_0.8Co_0.2O₃ perovskite, and thermal treated at 1100 °C for 2 h. The Ni-modified perovskite catalyst was mixed with a CGO powder and deposited on a CGO electrolyte to form a composite catalytic layer with a proper triple-phase boundary. Anode reduction was carried out in-situ in H₂ at 800 °C for 2 h during cell conditioning. Electrochemical performance was recorded at different times during 100 h operation in dry propane. The Ni-modified perovskite showed significantly better performance than the Ni/CGO anode. A power density of about 300 mW cm⁻² was obtained for the electrolyte supported SOFC in dry propane at 800 °C. Structural investigation of the composite anode layer after SOFC operation indicated a modification of the perovskite structure and the occurrence of a La₂NiO₄ phase. The occurrence of metallic Ni in the Ni/CGO system caused catalyst deactivation due to the formation of carbon deposits.     

Graphitized mesoporous carbon supported Pt-SnO2 nanoparticles as a catalyst for methanol oxidation

A mesostructured composite catalyst, Pt-SnO₂ supported on graphitized mesoporous carbon (GMC), has been prepared and its electrochemical activity for methanol oxidation has been investigated. The materials were characterized by XRD, FESEM, TEM, EDX spectrum and N₂ sorption techniques. Cyclic voltammetry, chronoamperometry and steady-state polarization tests were adopted to characterize the electro-catalytic activities of the materials for methanol oxidation. The results show that, the overall methanol electro-oxidation catalytic activity of the mesostructured composite catalyst, 20 wt.% PtSnO₂ (1:1, mass ratio)/GMC, is obviously higher than that of 20 wt.% PtSnO₂/C with commercial carbon black as support under the same loading amount of Pt-SnO₂ catalysts, and is also much higher than that of commercial catalyst 20 wt.% Pt/C at half Pt using amount.     

Morphology and microstructure of spring-like carbon micro-coils/nano-coils prepared by catalytic pyrolysis of acetylene using Fe-containing alloy catalysts

Three-dimensional (3D) spring-like carbon nano-coils were obtained in high purity (nearly 100%) and high yield (20%) by the catalytic pyrolysis of acetylene at 750-790 °C using an Fe-based catalyst; 54Fe-38Cr-4Mn-4Mo or 71Fe-18Cr-8Ni-3Mo (SUS513). The morphologies and microstructure were examined in detail, and the growth mechanism is also discussed. The diameter of carbon fiber, from which the carbon nano-coils was formed, was 50-200 nm, the coil diameter 100-1000 nm, and the coil pitch 10-500 nm. The nano-coils were generally grown by a mono-directional growth mode, and laces with various morphologies were very commonly observed on the surface. It was observed that the spring-like carbon nano-coils are actually composed of two fused nano-coils.     

Morphologies and microstructures of tree-like carbon produced at different reaction conditions in a CVD process

Centimeter-size multi-branched tree-like carbon structures have been generated by the catalytic chemical vapor deposition of toluene using ferrocene as the catalyst precursor and investigated by means of SEM, TEM, and EDX. It is found that a temperature of 1000-1200 °C and a carrier gas flow rate of 1000-2500 ml/min are necessary for the generation of the carbon trees. Their morphologies and microstructures change greatly with the changing reaction conditions. The fractal dimensions of the trees are calculated to quantitatively investigate the influence of different reaction temperatures on the morphologies.     

Microstructure and anti-oxidation properties of multi-composition ceramic coatings for carbon/carbon composites

To protect carbon/carbon (C/C) composites from oxidation at elevated temperature, an effective WSi₂-CrSi₂-Si ceramic coating was deposited on the surface of SiC coated C/C composites by a simple and low-cost slurry method. The microstructures of the double-layer coatings were characterized by X-ray diffraction, scanning electron microscopy and energy dispersive spectroscopy analyses. The coating exhibited excellent oxidation resistance and thermal shock resistance. It could protect C/C composites from oxidation in air at 1773 K for 300 h with only 0.1 wt.% mass gain and endure the thermal shock for 30 cycles between 1773 K and room temperature. The excellent anti-oxidation ability of the double-layer WSi₂-CrSi₂-Si/SiC coating is mainly attributed to the dense structure of the coating and the formation of stable vitreous composition including SiO₂ and Cr₂O₃ produced during oxidation.     

Fixed- and fluidised-bed synthesis of coiled carbon fibres on an in situ generated H2S-modified Ni/Al2O3 catalyst from a NiSO4/Al2O3 precursor

NiSO₄/Al₂O₃ and NiO/Al₂O₃ catalyst precursors were formed by calcination of NiSO₄·6H₂O/Al₂O₃ at 500 and 800 °C, respectively. The catalyst precursor was reduced under H₂ and N₂ and then reacted under C₂H₂, H₂ and N₂ at 650 °C. Coiled carbon fibres were formed in fixed- and fluidised-bed reactors using the NiSO₄/Al₂O₃ catalyst precursor. Thermodynamic modelling using an infinite equilibrium stage construction predicted complete reduction of NiSO₄ to Ni and simultaneous H₂S formation occurs in both fixed- and fluidised-bed systems. XRD measurements confirmed that Ni was the only catalytically active crystalline species present at concentrations >0.5 wt.% (XRD detection limit) post-reduction, however XRF and XPS measurements additionally detected the presence of small quantities (<0.9 wt.% S) of S species. S is adsorbed onto the Ni surfaces during reduction when H₂S is released and dissociates on the Ni surface. Non-coiled carbon fibres produced on the Ni/Al₂O₃ catalyst formed from the NiO/Al₂O₃ precursor demonstrated that modification of Ni/Al₂O₃ with S is required for coiled carbon fibre synthesis.     

Catalytic filamentous carbon as supports for nickel catalysts

Ni catalysts supported on catalytic filamentous carbon (CFC) were studied in the model reaction of methane decomposition at 525 °C. The supports (CFC) were synthesized by decomposition of methane over metal catalysts (Ni, Ni-Cu, Co and Fe-Co-alumina) at 500-675 °C. The yield of secondary carbon was shown to reach 224 g/g_Ni on the Ni/CFC (Ni-Cu, 625 °C) catalyst. The stability and activity of the Ni/CFC catalysts for deposition of the secondary carbon at 525 °C depend both on textural properties of the support and on the surface structure of the CFC filaments. It seems that highly porous carbon supports are more suitable for development of Ni/CFC catalyst for methane decomposition. The catalytic properties of the supported Ni/CFC systems may be accounted for by generation of weak dispersive interactions between specifically shaped Ni crystallites 30-70 nm in size and basal planes on the surface of the carbon filament.     

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.     

A silica supported Fe-Co bimetallic catalyst prepared by the sol/gel technique: Operating conditions, catalytic properties and characterization

A Co/Fe catalyst was prepared using the sol/gel technique in order to study its catalytic activity and selectivity in the Fischer-Tropsch synthesis. The effect of a range of operation variables such as pressure, temperature and H₂/CO molar feed ratio on the catalytic performance of 40%Fe/60%Co/15 wt.%SiO₂/1.5 wt.%K catalyst was investigated. It was found that the optimum operating conditions is a H₂/CO = 2/1 molar feed ratio at 350 °C temperature and 3 bar pressure. Characterization of both precursor and calcined catalysts was carried out using XRD, SEM, EDS, TPR, BET surface area measurements and thermal analysis methods such as TGA and DSC. It was observed that all of the different operation variables influenced the structure, morphology and catalytic performance of the catalysts.     

Thermogravimetric studies of carbon nanofiber formation from methane at low temperature over Ni-based skeletal catalysts and the effect of substrate pre-carburization

Using thermogravimetry (TG) under conditions that minimize inhibition by the hydrogen produced, the intrinsic catalytic rates of skeletal Ni, pure and alloyed with solute metals Fe, Co, or Cu, were evaluated in methane decomposition to carbon nanofibers. In “standard” tests, i.e., after pre-reduction in H₂ and exposure to CH₄ directly at 450 °C, several catalysts reached stable activities exceeding 4 mg C/mg cat./h, comparable with literature values obtained at 500 °C or above. TG evidence is presented for partial bulk carburization of Ni in CH₄ below 350 °C, which leads to substantially increased coking rates. TEM evidence supports the view that carburization promotes catalyst particle disintegration, thereby inducing faster and more stable nanofiber growth. Irregularities in alloy response to carburization are interpreted in terms of the stability of the respective mixed-metal carbides. TEM also shows that alloying changes the metal nanocrystallite shape (habit), with consequences for the carbon nanofiber structure. Evidence for the easy dissociation of CH₄ is corroborated by direct catalyst activation in the absence of H₂. Reduction begins in pure hydrocarbon around 300 °C and leads to coking activities at 450 °C comparable to those for samples pre-reduced in H₂. Skeletal metal catalysts offer distinct advantages in low-temperature natural gas conversion.     

Effect of heat treatment on the performance of TiO2-Pt/CNT catalysts for methanol electro-oxidation

TiO₂-Pt/CNT catalysts before and after heat treatment were prepared. Their catalytic activities for methanol and CO electro-oxidation were studied in detail. The results showed that the proper amount of hydrous TiO₂ in TiO₂-Pt/CNTs (e.g. heated at 200 °C for 2 h) was favorable for enhancing the catalytic activity of Pt/CNTs, which provided evidence for bi-functional mechanism. The studies on the catalysts with different TiO₂/Pt molar ratio displayed that the optimum molar ratio varied with the increase of heat treatment temperature. It was found that the optimum molar ratio of TiO₂/Pt was at 1:2 for the catalysts without heat treatment and was at 1:1 for the catalysts by heat treatment at 500 °C. This fact was ascribed to the difference in compact degree between TiO₂ and Pt/CNTs before and after heat treatment. Considering the influence of heating temperature, it was found that TiO₂-Pt/CNT catalyst heated at 200 °C for 2 h had better catalytic activity for methanol oxidation.