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INTRODUCTION
Before 1991, only 3 forms of carbon allotropes were known: diamond, graphite and
fullerene. It was in this year that Iijima discovered this very important form of
carbon allotrope known as Carbon Nanotubes. After a couple of years, he observed
Single Walled Nano Tubes (SWNTs) which opened the gates of immense research
possibilities in this field. Many applications have been developed since then and
the unique physical and chemical properties of Nanotubes have been unraveled.
In a SWNT a cylinder of graphene sheet is formed by rolling over to a diameter of
approximately 1.4 nm while in a Multi Walled Nano Tube (MWNT) there are
concentric cylinders having a separation of 0.34-0.36 nm. The force binding the
nanotubes together into bundles is strong Van Der Walls force therefore their
tensile strength is approximately a hundred times that of steel. The Youngs
modulus value is 1.2 TPa.
Arc Discharge method was initially used for the production of C 60 fullerenes. It is
most common and easy method to produce carbon nanotubes. This method
produces CNTs by arc vaporization of carbon rods as electrodes, separated by
distance of approximately 1 mm, in an enclosure of inert gas and low pressure. A
direct current of 50-100A and potential difference 20V is used. The disadvantage
of this method is that it produces a complex mixture of different components
which is difficult to separate and requires further purification.
Tiny-high quality nanotubes were prepared by HiPco continuously but the methods
of HiPco and CoMoCat are generally used only for scientific purposes.
Single and defect free SWNTs have not obtained in previous methods. For
nanotubes to be of any use, it should be defect free and it requires large scale
synthesis of nanotubes. CVD can be the solution for these problems. Carbon rich
gases are used as carbon feedstock in CVD. Efficiency of CVD is high compared to
other methods. By controlling different parameters in CVD experiments, it is
possible to obtain control over the formation of different types of nanotubes. On
supported transition-metal oxide catalysts, high quality SWNT were formed by
chemical vapor deposition of methane. Various factors are involved in
production of SWNT.
METHODS
In electric arc method, two graphite rods as electrodes at different potential are
placed in an enclosure filled with inert gas at low pressure(50-700 mbar).Anode
is moved closer to cathode until an arc appears and the electrodes are kept at
the distance of 1 mm for the whole duration of the process. After
depressurization and cooling of the chamber the nanotubes together with the
by-products are collected. Most nanotubes deposit on cathode. The efficiency
of this method is approximately 60%.
In the milling and annealing method for the synthesis of carbon nanotubes, dry
milling of commercial graphite powder is done at 900 RPM and 78G centrifugal
force for 5 hours. The nucleation process was catalyzed by 4 wt.% Iron. The
crystalline hexagonal graphite gets converted to amorphous carbon powder
which is then annealed isothermally at 1600 degrees Celsius in presence of
inert Argon for 6 hours. Presence of multiwalled carbon nanotubes are reported
post annealing process.
In the HiPco method, Fe(CO)5 catalyst was used with carbon-monoxide at high
pressure to obtain very thin single-walled carbon nanotubes. The nanotubes
obtained in this method had minimum structural defects and very high intrinsic
selectivity. Carbon nanotubes were produced at a high rate with minimum
wastage of carbon-monoxide.
The CoMoCat method gets its name from the catalyst mixture of cobalt and
molybdenum. The temperature required for this method was 700-950C for the
decomposition of CO into carbon and CO2 and this method produced no by-
products.
CONCLUSIONS
Arc-discharge method suffers from disadvantage of being an economically
unfeasible method for large scale production of carbon nanotubes, in spite of
yielding high quality carbon nanotubes. Ball milling and annealing method
produces multiwalled nanotubes but is an easier method of generation of
nanotubes. Chemical Vapor Deposition is the most advantageous economic
method for large scale production of high-purity Single Walled Carbon
Nanotubes (SWNT). Different innovations and research in catalysts and carbon
feedstock bring in the scope of diverse possibilities. Alternatives of CVD
process such as CoMoCAT & HiPco can be replicated to large scale
processes with continuous process & high yield.
2. Guler and Evin, Carbon nanotubes formation by short-time ball milling and annealing of graphite,
OPTOELECTRONCS AND ADVANCED MATERALS RAPID COMMUNICATIONS Vol. 6, No. 1-2, January-
February 2012, p. 183 187.
3. Shi, Lian, Zhou, Gu, Zhang, Iijima, Zhou, Yue and S. Zhang, Mass-production of single-wall carbon
nanotubes by arc discharge method, Carbon 37 (1999) 14491453.