Large Scale CVD Synthesis of Single-Walled Carbon Nanotubes

TLDR

The synthesis of bulk, high‑quality single‑walled carbon nanotubes is achieved by optimizing the chemical composition and textural properties of the catalyst used in methane CVD. This work aims to advance the production of kilogram‑scale, defect‑free SWNT materials through straightforward CVD processes. Catalysts were generated by systematically varying the catalytic metal compounds and support materials. The optimized Fe/Mo bimetallic catalyst on a novel silica–alumina multicomponent support delivers gram quantities of defect‑free SWNTs in about 0.5 h, featuring high surface area and large mesopore volume.

Abstract

The synthesis of bulk amounts of high quality single-walled carbon nanotubes (SWNTs) is accomplished by optimizing the chemical compositions and textural properties of the catalyst material used in the chemical vapor deposition (CVD) of methane. A series of catalysts are derived by systematically varying the catalytic metal compounds and support materials. The optimized catalysts consist of Fe/Mo bimetallic species supported on a novel silica−alumina multicomponent material. The high SWNT yielding catalyst exhibits high surface-area and large mesopore volume at elevated temperatures. Gram quantities of SWNT materials have been synthesized in ∼0.5 h using the optimized catalyst material. The nanotube material consists of individual and bundled SWNTs that are free of defects and amorphous carbon coating. This work represents a step forward toward obtaining kilogram scale perfect SWNT materials via simple CVD routes.