An Updated Review of Synthesis Parameters and Growth Mechanisms for Carbon Nanotubes in Fluidized Beds

Role of Hydrogen in Ethylene-Based Synthesis of Single-Walled Carbon Nanotubes

We examined the effect of hydrogen on the growth of single-walled carbon nanotubes in the aerosol (a specific case of the floating catalyst) chemical vapor deposition process using ethylene as a carbon source and ferrocene as a precursor for a Fe-based catalyst. With a comprehensive set of physical methods (UV-vis-NIR and Raman spectroscopies, transmission electron microscopy, scanning electron microscopy, differential mobility analysis, and four-probe sheet resistance measurements), we showed hydrogen to inhibit ethylene pyrolysis extending the window of synthesis parameters. Moreover, the detailed study at different temperatures allowed us to distinguish three different regimes for the hydrogen effect: pyrolysis suppression at low concentrations (I) followed by surface cleaning/activation promotion (II), and surface blockage/nanotube etching (III) at the highest concentrations. We believe that such a detailed study will help to reveal the complex role of hydrogen and contribute toward the synthesis of single-walled carbon nanotubes with detailed characteristics.

JA, Nasibulin AG. Bithiophene as a Sulfur-Based Promotor for the Synthesis of Carbon Nanotubes and Carbon-Carbon Composites

We assess bithiophene (C8H6S2) as a novel sulfur-based promotor for the growth of single-walled carbon nanotubes (SWCNTs) in the aerosol (floating catalyst) CVD method. Technologically suitable equilibrium vapor pressure and an excess of hydrocarbon residuals formed under its decomposition make bithiophene an attractive promoter for the production of carbon nanotubes in general and specifically for ferrocene-based SWCNT growth. Indeed, we detect a moderate enhancement in the carbon nanotube yield and a decrease in the equivalent sheet resistance of the films at a low bithiophene content, indicating the improvement of the product properties. Moreover, the relatively high concentrations and low temperature stability of bithiophene result in non-catalytical decomposition, leading to the formation of pyrolytic carbon deposits; the deposits appear as few-layer graphene structures. Thus, bithiophene pyrolysis opens a route for the cheap production of hierarchical composite thin films comprising carbon nanotubes and few-layer graphene, which might be of practical use for hierarchical adsorbents, protective membranes, or electrocatalysis.

Chemical vapor deposition of 2D materials: A review of modeling, simulation, and machine learning studies

Chemical vapor deposition (CVD) is extensively used to produce large-area two-dimensional (2D) materials. Current research is aimed at understanding mechanisms underlying the nucleation and growth of various 2D materials, such as graphene, hexagonal boron nitride (hBN), and transition metal dichalcogenides (e.g., MoS₂/WSe₂). Herein, we survey the vast literature regarding modeling and simulation of the CVD growth of 2D materials and their heterostructures. We also focus on newer materials, such as silicene, phosphorene, and borophene. We discuss how density functional theory, kinetic Monte Carlo, and reactive molecular dynamics simulations can shed light on the thermodynamics and kinetics of vapor-phase synthesis. We explain how machine learning can be used to develop insights into growth mechanisms and outcomes, as well as outline the open knowledge gaps in the literature. Our work provides consolidated theoretical insights into the CVD growth of 2D materials and presents opportunities for further understanding and improving such processes

Recent Advances on Properties and Utility of Nanomaterials Generated from Industrial and Biological Activities

Today is the era of nanoscience and nanotechnology, which find applications in the field of medicine, electronics, and environmental remediation. Even though nanotechnology is in its emerging phase, it continues to provide solutions to numerous challenges. Nanotechnology and nanoparticles are found to be very effective because of their unique chemical and physical properties and high surface area, but their high cost is one of the major hurdles to its wider application. So, the synthesis of nanomaterials, especially 2D nanomaterials from industrial, agricultural, and other biological activities, could provide a cost-effective technique. The nanomaterials synthesized from such waste not only minimize pollution, but also provide an eco-friendly approach towards the utilization of the waste. In the present review work, emphasis has been given to the types of nanomaterials, different methods for the synthesis of 2D nanomaterials from the waste generated from industries, agriculture, and their application in electronics, medicine, and catalysis.

Machine Learning for Tailoring Optoelectronic Properties of Single-Walled Carbon Nanotube Films

A machine learning technique, namely, support vector regression, is implemented to enhance single-walled carbon nanotube (SWCNT) thin-film performance for transparent and conducting applications. We collected a comprehensive data set describing the influence of synthesis parameters (temperature and CO₂ concentration) on the equivalent sheet resistance (at 90% transmittance in the visible light range) for SWCNT films obtained by a semi-industrial aerosol (floating-catalyst) CVD with CO as a carbon source and ferrocene as a catalyst precursor. The predictive model trained on the data set shows principal applicability of the method for refining synthesis conditions toward the advanced optoelectronic performance of multiparameter processes such as nanotube growth. Further doping of the improved carbon nanotube films with HAuCl₄ results in the equivalent sheet resistance of 39 Ω/□-one of the lowest values achieved so far for SWCNT films.

Can single-walled carbon nanotube diameter be defined by catalyst particle diameter?

The need of designing and controlling single-walled carbon nanotube (SWCNT) properties is a challenge in a growing nanomaterials-related industry. Recently, great progress has been made experimentally to selectively control SWCNT diameter and chirality. However, there is not yet a complete understanding of the synthesis process and there is a lack of mathematical models that explain nucleation and diameter selectivity of stable carbon allotropes. Here, in-situ analysis of chemical vapor deposition SWCNT synthesis confirms that the nanoparticle to nanotube diameter ratio varies with the catalyst particle size. It is found that the tube diameter is larger than that of the particle below a specific size (d_c ≈ 2nm) and above this value is smaller than particle diameters. To explain these observations, we develop a statistical mechanics based model that correlates possible energy states of a nascent tube with the catalyst particle size. This model incorporates the equilibrium distance between the nucleating SWCNT layer and the metal catalyst (e.g. Fe, Co, Ni) evaluated with density functional theory (DFT) calculations. The theoretical analysis explains and predicts the observed correlation between tube and solid particle diameters during growth of supported SWCNTs. This work also brings together previous observations related to the stability condition for SWCNT nucleation. Tests of the model against various published data sets and our own experimental results show good agreement, making it a promising tool for evaluating SWCNT synthesis processes.

Synthesis and growth mechanism of carbon nanotubes growing on carbon fiber surfaces with improved tensile strength

An effective approach has been developed for the catalytic decomposition of acetylene (C₂H₂) by chemical vapor deposition (CVD), to achieve homogeneous growth of carbon nanotubes (CNTs) on the surfaces of carbon fibers. The morphology of CNTs grown on carbon fiber surfaces was observed by a scanning electron microscope and high-resolution transmission electron microscope, which revealed the uniform coverage of CNTs on the carbon fiber surfaces. The single fiber tensile test demonstrated that the tensile strength of carbon fibers could be increased by more than 12% with the catalytic growth of CNTs on their surface. The reparation of the damage caused during the formation of catalyst nanoparticles, and the cross-link of neighboring graphite crystallites induced by CNTs all occurred during the CVD process, which were considered to be the main reasons for improvement. The growth mechanism model of CNTs formation was established based on the thermodynamics principle and the interface microstructure of CNT-grown carbon fiber, illuminating the detailed mechanism for the growth of CNTs and the change of the shape of catalyst particles.

A Review of Carbon Nanomaterials' Synthesis via the Chemical Vapor Deposition (CVD) Method

Carbon nanomaterials have been extensively used in many applications owing to their unique thermal, electrical and mechanical properties. One of the prime challenges is the production of these nanomaterials on a large scale. This review paper summarizes the synthesis of various carbon nanomaterials via the chemical vapor deposition (CVD) method. These carbon nanomaterials include fullerenes, carbon nanotubes (CNTs), carbon nanofibers (CNFs), graphene, carbide-derived carbon (CDC), carbon nano-onion (CNO) and MXenes. Furthermore, current challenges in the synthesis and application of these nanomaterials are highlighted with suggested areas for future research.

Synthesis of Multi-Walled Carbon Nanotubes from Plastic Waste Using a Stainless-Steel CVD Reactor as Catalyst

The disposal of non-biodegradable plastic waste without further upgrading/downgrading is not environmentally acceptable and many methods to overcome the problem have been proposed. Herein we indicate a simple method to make high-value nanomaterials from plastic waste as a partial solution to the environmental problem. Laboratory-based waste centrifuge tubes made of polypropylene were chosen as a carbon source to show the process principle. In the process, multi-walled carbon nanotubes (MWCNTs) were synthesized from plastic waste in a two-stage stainless steel 316 (SS 316) metal tube that acted as both reactor vessel and catalyst. The steel reactor contains Fe (and Ni, and various alloys), which act as the catalyst for the carbon conversion process. The reaction and products were studied using electron probe microanalysis, thermogravimetric analysis, Raman spectroscopy and transmission electron microscopy and scanning electron microscopy. Optimization studies to determine the effect of different parameters on the process showed that the highest yield and most graphitized MWCNTs were formed at 900 °C under the reaction conditions used (yield 42%; Raman I_D/I_G ratio = 0.48). The high quality and high yield of the MWCNTs that were produced in a flow reactor from plastic waste using a two stage SS 316 chemical vapor deposition (CVD) furnace did not require the use of an added catalyst.

Toward the suppression of cellular toxicity from single-walled carbon nanotubes

In the multidisciplinary fields of nanobiology and nanomedicine, single-walled carbon nanotubes (SWCNTs) have shown great promise due to their unique morphological, physical and chemical properties. However, understanding and suppressing their cellular toxicity is a mandatory step before promoting their biomedical applications. In light of the flourishing recent literature, we provide here an extensive review on SWCNT cellular toxicity and an attempt to identify the key parameters to be considered in order to obtain SWCNT samples with minimal or no cellular toxicity.

Mathematical Modeling of Carbon Nanotubes Formation in Fluidized Bed Chemical Vapor Deposition

This study investigates mathematical modeling of carbon nanotubes (CNTs) formation on catalyst particulate in a fluidized bed chemical vapor deposition (FBCVD) reactor. The mass of CNTs formed corresponds to the catalyst activity directly. The catalyst deactivation occurs as active sites are occupied by CNTs and thus causes unsteady state behavior of the process. The effects of catalyst loading (as bed height) as well as reaction temperature on the reaction progressing were investigated. The model, validated with our experimental data, indicates a good accuracy to predict the yield of CNTs formation for a given operating conditions. The model presented also can predict the optimized time as well as the suitable amount of catalyst loading to produce CNTs for a given reactor conditions.

Atomic scale simulation of carbon nanotube nucleation from hydrocarbon precursors

Atomic scale simulations of the nucleation and growth of carbon nanotubes is essential for understanding their growth mechanism. In spite of over twenty years of simulation efforts in this area, limited progress has so far been made on addressing the role of the hydrocarbon growth precursor. Here we report on atomic scale simulations of cap nucleation of single-walled carbon nanotubes from hydrocarbon precursors. The presented mechanism emphasizes the important role of hydrogen in the nucleation process, and is discussed in relation to previously presented mechanisms. In particular, the role of hydrogen in the appearance of unstable carbon structures during in situ experimental observations as well as the initial stage of multi-walled carbon nanotube growth is discussed. The results are in good agreement with available experimental and quantum-mechanical results, and provide a basic understanding of the incubation and nucleation stages of hydrocarbon-based CNT growth at the atomic level.

Atomic scale simulation of the nucleation and growth of carbon nanotubes is essential for understanding their growth mechanism. Here, the authors look at cap nucleation of nanotubes from hydrocarbon precursors, specifically probing the role of hydrogen in the early stages of growth.

The effect of CO2 on the CVD synthesis of carbon nanomaterials using fly ash as a catalyst

Carbon nanomaterials (CNMs) can be derived from waste materials such as: coal fly ash and CO₂, with CO₂ and C₂H₂ as carbon sources respectively.

Porous and strong three-dimensional carbon nanotube coated ceramic scaffolds for tissue engineering

A method to coat high-quality uniform coatings of carbon nanotubes throughout 3D porous structures is developed. Testing of their physical and biological properties demonstrate their potential for application in tissue engineering.

Controlling pyridinic, pyrrolic, graphitic, and molecular nitrogen in multi-wall carbon nanotubes using precursors with different N/C ratios in aerosol assisted chemical vapor deposition

The change in the N/C ratio in feedstock allows controlling nitrogen species incorporation into multi-wall carbon nanotubes during CCVD.

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.

The Effect of Catalyst on Carbon Nanotubes (CNTs) Synthesized by Catalytic Chemical Vapor Deposition (CVD) Technique

Catalyst plays a crucial role in determining the characteristics of carbon nanotubes (CNTs) produced by using thermal catalytic chemical vapor deposition (CVD). It is essential to investigate how the catalyst preparation affects the characteristics of CNTs because certain application demands specific size for optimum performance. This study reports the effect of the types of catalyst and the duration of the catalyst pre-treatment (wet etching time, dry etching time and ball milling) on the diameter of CNTs. The synthesized CNTs samples were characterized by scanning and transmission electron microscopy and Raman spectroscopy. Wet etching (2M hydrofluoric acid) time was varied from 1 to 2.5 hrs and the diameter range was found to be in the range of 23 to 52 nm. The diameter range for CNTs produced for 3 hrs and 5 hrs of dry etching treatment (with ammonia gas) are 38 to 51 nm and 23 to 48 nm, respectively. The diameter size of CNTs produced using Ni (14 to 25 nm) was found to be smaller than Fe (38 to 51 nm). There is a significant decrease in the diameter of CNTs by prolonging the wet etching period. Shorter and curly shaped CNTs can also be obtained by using Ni as the catalyst. Keywords: chemical vapor deposition, carbon nanotubes, catalyst pretreatment

Recent progress on the growth mechanism of carbon nanotubes: a review

Tremendous progress has been achieved during the past 20 years on not only improving the yields of carbon nanotubes and move progressively towards their mass production, but also on gaining a profound fundamental understanding of the nucleation and the growth processes. Parameters that influence the yield but also the quality (e.g., microstructure, homogeneity within a batch) are better understood. The influence of the carbon precursor, the reaction conditions, the presence of a catalyst, the chemical and physical status of the latter, and other factors have been extensively studied. The purpose of the present Review is not to list all the experiments reported in the literature, but rather to identify trends and provide a comprehensive summary on the role of selected parameters. The role of the catalyst occupies a central place in this Review as a careful control of the metal particle size, particle dispersion on the support, the metastable phase formed under reaction conditions, its possible reconstruction, and faceting strongly influence the diameter of the carbon nanotubes, their structure (number of walls, graphene sheet orientation, chirality), their alignment, and the yield. The identified trends will be compared with recent observations on the growth of graphene. Recent results on metal-free catalysts will be analyzed from a different perspective.

Striking influence of the catalyst support and its acid-base properties: new insight into the growth mechanism of carbon nanotubes

In the accepted mechanisms of carbon nanotube (CNT) growth by catalytic chemical vapor deposition (CCVD), the catalyst support is falsely considered as a passive material whose only role is to prevent catalytic particles from coarsening. The chemical changes that occur to the carbon source molecules on the surface are mainly overlooked. Here, we demonstrate the strong influence of the support on the growth of CNTs and show that it can be tuned by controlling the acid-base character of the support surface. This finding largely clarifies the CCVD growth mechanism. The CNTs' growth stems from the support where the presence of basic sites catalyzes the aromatization and reduces the complexity of CNT precursor molecules. On basic supports, the growth is activated and CNTs are more than 1000 times longer than those produced on acidic supports. These results could be the bedrock of future development of more efficient growth of CNTs on surfaces of functional materials. Finally, the modification of the aciditiy of the catalyst support during the super growth process is also discussed.

Catalytic CVD Synthesis of Carbon Nanotubes: Towards High Yield and Low Temperature Growth

The catalytic chemical vapor deposition (CCVD) is currently the most flexible and economically attractive method for the growth of carbon nanotubes. Although its principle is simple, the precisely controlled growth of carbon nanotubes remains very complex because many different parameters influence the growth process. In this article, we review our recent results obtained on the synthesis of carbon nanotubes via CCVD. We discuss the role of the catalyst and the catalyst support. Our recent results obtained from the water assisted growth and the equimolar C₂H₂-CO₂ reaction are also discussed. Both procedures lead to significantly enhanced carbon nanotube growth. In particular, the latter allows growing carbon nanotubes on diverse substrate materials at low temperatures.