WO2024157274A1 - A reaction apparatus arrangement for generation of single wall carbon nanotubes - Google Patents

A reaction apparatus arrangement for generation of single wall carbon nanotubes Download PDF

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Publication number
WO2024157274A1
WO2024157274A1 PCT/IN2024/050027 IN2024050027W WO2024157274A1 WO 2024157274 A1 WO2024157274 A1 WO 2024157274A1 IN 2024050027 W IN2024050027 W IN 2024050027W WO 2024157274 A1 WO2024157274 A1 WO 2024157274A1
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injector
arrangement
stream
catalyst
gas
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PCT/IN2024/050027
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French (fr)
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Gadhadar Reddy
Anto Godwin
Robert Kelley Bradley
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NoPo Nanotechnologies India Private Limited
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    • CCHEMISTRY; METALLURGY
    • C01INORGANIC CHEMISTRY
    • C01BNON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B32/00Carbon; Compounds thereof
    • C01B32/15Nano-sized carbon materials
    • C01B32/158Carbon nanotubes
    • C01B32/159Carbon nanotubes single-walled
    • CCHEMISTRY; METALLURGY
    • C01INORGANIC CHEMISTRY
    • C01BNON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B32/00Carbon; Compounds thereof
    • C01B32/15Nano-sized carbon materials
    • C01B32/158Carbon nanotubes
    • C01B32/16Preparation
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B82NANOTECHNOLOGY
    • B82YSPECIFIC USES OR APPLICATIONS OF NANOSTRUCTURES; MEASUREMENT OR ANALYSIS OF NANOSTRUCTURES; MANUFACTURE OR TREATMENT OF NANOSTRUCTURES
    • B82Y40/00Manufacture or treatment of nanostructures
    • CCHEMISTRY; METALLURGY
    • C01INORGANIC CHEMISTRY
    • C01BNON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B2202/00Structure or properties of carbon nanotubes
    • C01B2202/02Single-walled nanotubes

Definitions

  • the invention relates generally to the field of generation of single wall carbon nanotubes, and more particularly to a reaction apparatus arrangement for generation of single wall carbon nanotubes.
  • Carbon atoms can bond together in various ways, resulting in a number of allotropic forms of carbon with different physical properties.
  • the known allotropes include graphite, diamond, fullerenes, nanotubes and graphene.
  • carbon nanotubes are considered as the ultimate engineering material because of its unique and distinct electronic, mechanical and material characteristics.
  • SWCNTs single-walled carbon nanotubes
  • MWCNTs multi-walled carbon nanotubes
  • Singlewall Carbon nanotubes can be considered as graphene sheets seamlessly rolled up to form hollow cylinders with diameter in nanometers and length in microns.
  • the unique structure of the SWCNT imparts it properties including but not limited to high thermal conductivity, high electrical conductivity, high tensile strength, high elasticity, high flexibility and low thermal expansion coefficient.
  • SWCNT finds application in various domains including but not limited to composite materials and reinforced plastics, industrial coatings, tires and rubber technical goods, structural materials, materials for electrochemical power sources, adhesive and lubricants, anti-static plastics, transparent conductive films and cables.
  • Arc-discharge deposition method for producing SWCNT, metal catalyst coated graphite rod acting as a negative cathode and a pure graphite acting as positive anode, are placed a few millimeters apart and are evaporated using a high current to form carbon products.
  • Arc-discharge deposition is capable of synthesizing CNTs into large yield quantity (gram quantities) and in lengths greater than 40 pm. Disadvantages of the technique include production of large quantities of impure SWCNT with structural defects.
  • CoMoCAT Cobalt-molybdenum catalyst
  • HiPCO high-pressure carbon monoxide
  • CoMoCAT Cobalt-molybdenum catalyst
  • CoMoCAT Cobalt-molybdenum catalyst
  • the method is easy to control and produces SWCNT with high- purity.
  • the disadvantages of the method include low yield making it commercially unviable for industrial use and batch process leading to poor consistency across batches.
  • the HiPCO production technology employs a floating catalyst approach, whereby the growth catalyst is formed in situ during the production process.
  • Carbon nanotubes are produced from the disproportionation of carbon monoxide over catalytic iron nanoparticles at 1 ,323 K and 450 psia.
  • the method yields small diameter nanotubes with high purity.
  • the disadvantages include high energy consumption and high susceptibility of the quartz tube for breakage under pressure.
  • FIG. 1 shows a schematic diagram of a reaction apparatus arrangement for generation of single wall carbon nanotubes, according to an embodiment of the invention.
  • FIG. 2 shows a schematic representation of an injector for generation of single wall carbon nanotubes, according to an embodiment of the invention.
  • FIG. 3 shows a schematic representation of an injector for generation of single wall carbon nanotubes, according to an alternate embodiment of the invention.
  • FIG. 4 shows a schematic representation of an injector for generation of single wall carbon nanotubes, according to another embodiment of the invention.
  • FIG. 5 shows a flow diagram for generation of single wall carbon nanotubes, according to an embodiment of the invention.
  • FIG. 6 show a TGA plot of single wall carbon nanotubes obtained by the reaction apparatus arrangement, according to an embodiment of the invention.
  • FIG. 7 shows a SEM image of single wall carbon nanotube obtained by the reaction apparatus arrangement, according to an embodiment of the invention.
  • FIG. 8 shows a Raman spectrum of single wall carbon nanotube obtained by the reaction apparatus arrangement, according to an embodiment of the invention.
  • FIG. 9 shows a UV Vis NIR Spectrum of single wall carbon nanotube obtained by the reaction apparatus arrangement, according to an embodiment of the invention.
  • the reaction apparatus arrangement includes an injector tube having a broad end and a narrow end, an injector having a first end wherein the first end is configured to receive the narrow end of the injector tube, a means for circulation of gas formed on the walls of the injector, a hollow chamber for the reaction to occur and a second end and an inner tube having a diameter lesser than the diameter of the second end of the injector.
  • the difference in diameter between the inner tube and the second end of the injector allows for thermal expansion of the inner tube into the hollow chamber of the injector.
  • the hollow chamber of the injector is configured for mixing of the stream of CO maintained at temperature of 850°C to 1200°C and the stream of CO along with the catalyst maintained at a temperature ranging from 6°C to 100°C and generating single wall carbon nanotubes through disproportionation reaction of carbon monoxide over the catalyst.
  • Fig.1 shows a schematic diagram of a reaction apparatus arrangement for generation of single wall carbon nanotubes according to an embodiment of the invention.
  • the reaction apparatus arrangement includes an injector tube 1 having a broad end 1 a and a narrow end 1 b, an injector 3 having a first end 3a, a means for circulation of gas formed on the walls of the injector 3, a hollow chamber 3b for the reaction to occur and a second end 3c and an inner tube 5.
  • the first end 3a of the injector 3 is configured to receive the narrow end 1 b of the injector tube 1 .
  • the diameter of the inner tube 5 is lesser than the diameter of the second end 3c of the injector 3.
  • the reaction apparatus arrangement further includes an outer tube 7, a cylindrical heating element 9, surrounding the outer tube 7 and an insulating jacket 11 covering the cylindrical heating element 11 .
  • the outer tube 7 has an inlet 17 at one end and an outlet 19 at the opposite end.
  • the inlet 17 accommodates injector tube 1 and the outlet 19 accommodates inner tube 5.
  • the narrow end 1 b of the injector tube 1 is detachably attached to the first end 3a of the injector 3.
  • the detachable attachment to the injector 3 is achieved by either push-fit or threaded connection.
  • the injector tube 1 is configured for flow of stream of CO gas along with a catalyst to the injector 3.
  • the stream of CO gas along with the catalyst is maintained at a temperature below the decomposition temperature of the catalyst.
  • the temperature of the stream of CO gas along with the catalyst is maintained at temperature below the decomposition temperature of the catalyst by using cooling methods known in the art such as air cooling or water cooling. In one embodiment of the invention, cooling is achieved by water cooling preferably through circulating water in the injector tube 1 .
  • the catalyst is broadly selected from a group of chemicals such as iron, nickel, cobalt, molybdenum carbonyl, ferrocene.
  • the catalyst is iron pentacarbonyl.
  • the catalyst is nickel pentacarbonyl.
  • the temperature of the stream of CO gas along with the catalyst is maintained at a temperature ranging from 6°C to 100°C.
  • the outlet 19 of the outer tube 7 is connected to a CO gas flow line for counter current flow of CO gas into the outer tube 7.
  • the cylindrical heating element 9 surrounding the outer tube 7 heats the CO gas flowing counter currently in the outer tube to a temperature ranging from 850 - 1200 °C. The heated stream of CO gas is then injected into the injector 3.
  • the injector 3 is configured for mixing of the stream of CO gas along with the catalyst maintained at temperature ranging from 6°C to 100°C with the stream of CO gas maintained at temperature ranging from 850 - 1200 °C.
  • the mixing is achieved through the means for circulation of gas formed on the walls of injector 3 and includes a central hole 13 for flow of stream of CO gas along with the catalyst and a plurality of circumferentially or annular placed holes 15 for flow of the heated stream of CO gas.
  • the mixed stream of gases is injected into the hollow chamber 3b of the injector 3 for reaction to occur.
  • the hollow chamber 3b acts as reaction zone for the generation of single wall carbon nanotubes.
  • the single wall carbon nanotubes are generated through disproportionation reaction of carbon monoxide over the catalyst.
  • the generated single wall carbon nanotubes are then collected by the inner tube 5.
  • the inner tube 5 is a cylindrical tube with the diameter ranging from 6 mm to 20 mm.
  • the length of the inner tube varies from 1000mm to 2500mm.
  • the inner tube is made up of metal alloys including but not limited to alloy of nickel/chromium, alloy of nickel/chromium/molybdenum. Since, the inner tube 5 and the injector 3 is made of metal alloys, during reaction at temperature of 900- 940 °C, the metal alloys tend to expand, the difference in diameter of the inner tube 5 with respect to the injector 3, allows the inner tube 5 to expand inside the hollow chamber 3b of the injector 3.
  • the use of metal alloys and the ability of the inner tube 5 to thermally expand inside the hollow chamber 3b of the injector allow reusability of the inner tube 5 for repeated operations.
  • the inner tube 5 is configured for receiving the generated single wall carbon nanotubes from the reaction zone of the injector 3.
  • the inner tube 5 is provided with an outlet 21 for continuous removal of the generated single wall carbon nanotubes.
  • FIG. 2 shows a schematic representation of an injector for generation of single wall carbon nanotubes, according to an embodiment of the invention.
  • the injector 3 is detachably attached to the injector tube 1 and is configured for receiving and mixing atleast two streams of gases at varying temperatures.
  • the injector 3 is tubular in shape with an outer diameter ranging from 30-40 mm and inner diameter ranging from 10-30 mm. The length of the injector varies from 30 mm to 100 mm.
  • the injector is made of alloy of metal including but not limited to alloy of nickel/chromium, alloy of nickel/chromium/molybdenum.
  • the injector 3 has a first end 3a, a means for circulation of the gas formed on the walls of the injector, a hollow chamber 3b and a second end 3c.
  • the first end 3a is a closed end and has a centrally placed hole 13.
  • the central hole 13 is configured for flow of stream of CO gas along with the catalyst, preferably iron pentacarbonyl.
  • the temperature of the stream of CO gas along with catalyst is maintained at a temperature below the decomposition temperature of the catalyst.
  • the second end 3c is an open end and is proximal to the inner tube 5.
  • the hollow chamber 3b acts as reaction zone for the generation of single wall carbon nano tubes.
  • the injector 3 is further provided with a plurality of holes 15 placed either circumferentially or on the annular surface of the second end 3c.
  • the plurality of holes 15 are configured for flow of the stream of CO gas maintained at temperature ranging from 850 - 1200 °C into the hollow chamber 3b of the injector 3.
  • the plurality of holes 15 are placed on the annular surface of the second end 3c of the injector and run axially along the length of injector 3 and bend at an angle of 90° proximal to the first end 3a to combine with the flow path of central hole 13.
  • the plurality of holes 15 are placed on the annular surface of the second end 3c of the injector and run axially along the length of injector 3 and bend at an angle of 45° proximal to the first end 3a to combine with the flow path of central hole 13 to enhance the mixing of the cold and hot stream of CO gas.
  • the plurality of holes 15 are placed circumferentially on the injector surface towards the first end 3a (Fig 3a). The plurality of holes 15 then run radially and combine with the flow path of central hole 13.
  • the plurality of holes 15 are placed circumferentially on the injector surface towards the first end 3a.
  • the plurality of holes 15 then run tangentially and combine with the flow path of central hole 13 (Fig 3b).
  • the hollow chamber 3b acts as a reaction zone, the stream of CO gas along with the catalyst maintained at temperature below the degradation temperature of the catalyst, coming from the central hole 13 mixes with the hot streams of CO gas coming from plurality of holes 15 and generate single wall carbon nano tubes through disproportionation reaction of carbon monoxide over the catalyst.
  • the injector 3 is provided in two parts (Fig. 4a).
  • the first end 3a of the injector is disjoint from the hollow chamber 3b, the first end 3a is connected to the hollow chamber 3b through a threaded connection or a push fit connection. Since the first end 3a of the injector is connected to the injector tube 1 wherein water or air cooling maintains the stream of CO along with catalyst at temperature below the decomposition temperature of the catalyst, the injector is cooler at this end and during the thermal expansion controls the diametrical expansion of the injector and helps in maintaining the gap.
  • the injector 3 is provided in three parts (Fig. 4b).
  • the first end 3a of the injector is provided in two parts, a first part (I) and a second part (II).
  • the first part (I) and the second part (II) are connected through a threaded connection or a push-fit connection.
  • the first part (I) is connected to the injector tube 1 and the second part (II) is detachably attached to the hollow chamber 3b through a threaded connection or a push-fit connection.
  • the first part (I) and the second part (II) are made of two different metals or alloys to have control over the diametric expansion due to temperature difference.
  • FIG. 5 shows a flow diagram for generation of single wall carbon nanotubes, according to an embodiment of the invention.
  • Single wall carbon nanotubes are generated in the hollow chamber 3b of the injector by the reaction of CO gas maintained at temperature of 850 °C to 1200 °C with the stream of CO gas along with the catalyst. Formation of uniform diameter, high purity single carbon nanotubes requires, a high reaction temperature in the range of 900 °C to 1000 °C, preferably 950 °C, while the temperature of catalyst to be maintained at a temperature below the decomposition temperature of the catalyst, ranging between 6 °C to 100 °C .
  • the pressure of the reaction apparatus arrangement is maintained at a pressure of 10-50 bars.
  • the pressure of stream of CO gas the injector 3 through plurality of holes 15 is maintained at a pressure of 20-30 bars, while the pressure of stream of CO along with the catalyst is maintained at 15-60 bars.
  • the pressure in the reaction apparatus arrangement and the lines carrying the streams of CO gas and CO gas along with the catalyst is maintained through a compressor and a set of forward pressure regulators and backward pressure regulators.
  • a high pressure CO gas line (L1 ) at 40-60 bars is divided into two lines L2 (at 15-60 bars) and L3 (at 20-30 bars) through forward pressure regulator.
  • the line L3 maintained at 20-30 bars carrying CO gas enters the reactor through the outlet 19 of the outer tube 7 and gets heated up by the cylindrical heating element to a temperature of 950 °C.
  • the heated stream of CO gas from the outer tube 7 enters the injector 3 through the plurality of holes 15.
  • the line L2 maintained at 15-60 bars carrying CO gas enters a bubbler, where catalyst iron pentacarbonyl is generated and combines with the CO to form the stream of CO gas along with the catalyst.
  • the stream of CO gas along with the catalyst enters the reaction apparatus arrangement through the injector tube 1 and through central hole 13 enters into the injector 3.
  • the injector 3 mixes the hot stream of CO gas with the stream of CO along with the catalyst iron pentacarbonyl.
  • the iron pentacarbonyl and CO gets atomized.
  • the atomized metal atoms nucleate to form nanoparticles on which the nanotubes grow.
  • Carbon nanotubes are synthesized through reverse Boudouard reaction in the presence of catalyst iron cluster which are formed by the decomposition of iron carbonyl:
  • the generated single wall carbon nanotubes, byproduct CO2 and unreacted gas leaves the reactor through outlet 21 of the inner tube 5 and passes through various filters.
  • a nanotube filter removes and collects nanotubes, while a carbon dioxide filter, removes CO2.
  • the unreacted CO gas, through a back pressure regulator is maintained at 16-25 bars and is looped back to the compressor.
  • the single wall carbon nanotubes generated have diameter in the range of 0.8 nm to 1.2 nm with the length ranging 700nm to 1000nm. Characterization:
  • FIG. 6 show a TGA plot of single wall carbon nanotube obtained by the reactor, according to an embodiment of the invention.
  • TGA is used to validate SWCNT's purity.
  • the thermogram of the as-prepared materials would show multiple peaks corresponding to various temperatures of decomposition for SWCNT, the oxidation of catalyst particles and decomposition of SWCNT, the oxidation of catalyst particles and decomposition of carbonaceous agglomerates.
  • TGA analysis of graphite, fullerene, and nanotube samples shows that oxidation resistance rises as C-C bonding in nanotubes becomes stronger, since there are fewer dangling bonds that can be oxidized.
  • FIG. 7 shows a SEM image of single wall carbon nanotube obtained by the reactor, according to an embodiment of the invention.
  • the SEM image shows nanotubes magnified up to 200,000 times to visualize the bundles of the nanotubes.
  • the SEM image shows fibrous carbon nanotubes with clean tubes and very less amorphous carbon.
  • FIG. 8 shows a Raman spectrum of single wall carbon nanotube obtained by the reactor, according to an embodiment of the invention.
  • the figure shows Raman spectrum of the single wall carbon nanotube at an excitation wavelength of 514 nm.
  • the presence of a low frequency peak around 200 cm -1 in the Raman spectrum which corresponds to a SWCNT's radial breathing mode (RBM) and sets it apart from graphite.
  • This RBM characteristic is frequency-measured and is inversely proportional to nanotube radius (r).
  • the D band of the spectrum which denotes defects or disorder in the structure, corresponds to the peaks, seen around 1340cm -1 .
  • the peaks seen between 1550 and 1600 cm -1 are in the G band of the spectrum, which denotes the presence of graphene sheets in the sample and the graphitization of the sample.
  • This G band is divided into the G+ band and the G- band.
  • the G- curve is shaped differently for metallic and semiconducting SWCNTs.
  • the G+ signal indicates vibrational confinement by the tube's circumference. It is a characteristic that is unrelated to tube radius and is dependent on atomic movement in the graphene plane. Given that it originates from the second order harmonic of the D band, the line known as the G' band or 2D band is present around 2650 cm -1 . It shows the sample's long-range order.
  • the G-band appears to be divided due to the tube's curvature.
  • the G/D ratio of the nanotubes produced is 25.
  • FIG. 9 shows a UV Vis NIR Spectrum of single wall carbon nanotube obtained by the reactor, according to an embodiment of the invention.
  • the UV Vis NIR Spectrum shows a chirality shift favouring smaller diameter single wall carbon nanotubes.
  • the invention provides a production technology that produces small diameter, high purity and high quality carbon nanotubes, consumes less energy, is safe and can withstand high temperature and pressure.
  • the arrangement of the present invention can be used for HiPCO process.

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Abstract

The invention provides a reaction apparatus arrangement for generation of single wall carbon nanotubes, the arrangement includes an injector tube having a broad end and a narrow end, an injector and an inner tube. The injector includes a first end, a means for circulation of gas formed on the walls of the injector, a hollow chamber for the reaction to occur and a second end. The first end of the injector is configured to receive the narrow end of the injector tube. The diameter of the inner tube is lesser than the diameter of the second end of the injector to allow thermal expansion of the inner tube into the hollow chamber of the injector. The hollow chamber of the injector is configured for mixing of the stream of CO maintained at temperature of 850°C to 1200°C and the stream of CO along with the catalyst maintained at a temperature ranging from 6°C to 100°C and generating single wall carbon nanotubes.

Description

A REACTION APPARATUS ARRANGEMENT FOR GENERATION OF SINGLE WALL CARBON NANOTUBES
FIELD OF INVENTION
The invention relates generally to the field of generation of single wall carbon nanotubes, and more particularly to a reaction apparatus arrangement for generation of single wall carbon nanotubes.
BACKGROUND
Carbon atoms can bond together in various ways, resulting in a number of allotropic forms of carbon with different physical properties. The known allotropes include graphite, diamond, fullerenes, nanotubes and graphene. Of these, carbon nanotubes are considered as the ultimate engineering material because of its unique and distinct electronic, mechanical and material characteristics. There are basically two kinds of carbon nanotubes; single-walled carbon nanotubes (SWCNTs) and multi-walled carbon nanotubes (MWCNTs). The most important feature that distinguishes SWCNTs is that the wall of the nanotube consists of only one graphene layer. Hence, Singlewall Carbon nanotubes (SWCNT) can be considered as graphene sheets seamlessly rolled up to form hollow cylinders with diameter in nanometers and length in microns. The unique structure of the SWCNT imparts it properties including but not limited to high thermal conductivity, high electrical conductivity, high tensile strength, high elasticity, high flexibility and low thermal expansion coefficient. Owing to the wide range of desirable properties, SWCNT finds application in various domains including but not limited to composite materials and reinforced plastics, industrial coatings, tires and rubber technical goods, structural materials, materials for electrochemical power sources, adhesive and lubricants, anti-static plastics, transparent conductive films and cables.
Various methods and techniques of synthesis of single walled carbon nanotubes have been demonstrated and practiced like arc discharge, laser ablation, and catalytic chemical vapor deposition.
In arc-discharge deposition method, for producing SWCNT, metal catalyst coated graphite rod acting as a negative cathode and a pure graphite acting as positive anode, are placed a few millimeters apart and are evaporated using a high current to form carbon products. Arc-discharge deposition is capable of synthesizing CNTs into large yield quantity (gram quantities) and in lengths greater than 40 pm. Disadvantages of the technique include production of large quantities of impure SWCNT with structural defects.
In laser ablation method, graphite under intense laser pulses evaporates and primarily forms single-wall carbon nanotubes. Laser ablation method produce CNT with good diameter control and are pure with few defects. One significant disadvantage is that the method is commercially unviable as it requires expensive lasers and low yield per power.
Chemical vapour deposition is the most developed method for commercial production of SWCNT and involves catalytic deposition of carbon after heating of carbon bearing gas at high temperature. Cobalt-molybdenum catalyst (CoMoCAT) process and high-pressure carbon monoxide (HiPCO) process are most successful chemical vapour deposition methods for production of SWCNT. Cobalt-molybdenum catalyst (CoMoCAT) process involves growth of carbon nanotubes by the catalytic decomposition of carbon monoxide on silica supported, Co-Mo bimetallic catalyst particles, at 1 ,223 K and 150 psia. The method is easy to control and produces SWCNT with high- purity. The disadvantages of the method include low yield making it commercially unviable for industrial use and batch process leading to poor consistency across batches.
The HiPCO production technology employs a floating catalyst approach, whereby the growth catalyst is formed in situ during the production process. Carbon nanotubes are produced from the disproportionation of carbon monoxide over catalytic iron nanoparticles at 1 ,323 K and 450 psia. The method yields small diameter nanotubes with high purity. The disadvantages include high energy consumption and high susceptibility of the quartz tube for breakage under pressure.
Hence, there is a need for a production technology that produces small diameter, high purity, high quality carbon nanotubes, consumes less energy, is safe and is capable of withstanding high temperature and pressure.
BRIEF DESCRIPTION OF DRAWINGS
So that the manner in which the recited features of the invention can be understood in detail, some of the embodiments are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
FIG. 1 shows a schematic diagram of a reaction apparatus arrangement for generation of single wall carbon nanotubes, according to an embodiment of the invention.
FIG. 2 shows a schematic representation of an injector for generation of single wall carbon nanotubes, according to an embodiment of the invention.
FIG. 3 shows a schematic representation of an injector for generation of single wall carbon nanotubes, according to an alternate embodiment of the invention.
FIG. 4 shows a schematic representation of an injector for generation of single wall carbon nanotubes, according to another embodiment of the invention.
FIG. 5 shows a flow diagram for generation of single wall carbon nanotubes, according to an embodiment of the invention.
FIG. 6 show a TGA plot of single wall carbon nanotubes obtained by the reaction apparatus arrangement, according to an embodiment of the invention.
FIG. 7 shows a SEM image of single wall carbon nanotube obtained by the reaction apparatus arrangement, according to an embodiment of the invention. FIG. 8 shows a Raman spectrum of single wall carbon nanotube obtained by the reaction apparatus arrangement, according to an embodiment of the invention.
FIG. 9 shows a UV Vis NIR Spectrum of single wall carbon nanotube obtained by the reaction apparatus arrangement, according to an embodiment of the invention.
SUMMARY OF THE INVENTION
One aspect of the invention provides a reaction apparatus arrangement for generation of single wall carbon nanotubes. The reaction apparatus arrangement includes an injector tube having a broad end and a narrow end, an injector having a first end wherein the first end is configured to receive the narrow end of the injector tube, a means for circulation of gas formed on the walls of the injector, a hollow chamber for the reaction to occur and a second end and an inner tube having a diameter lesser than the diameter of the second end of the injector. The difference in diameter between the inner tube and the second end of the injector allows for thermal expansion of the inner tube into the hollow chamber of the injector. The hollow chamber of the injector is configured for mixing of the stream of CO maintained at temperature of 850°C to 1200°C and the stream of CO along with the catalyst maintained at a temperature ranging from 6°C to 100°C and generating single wall carbon nanotubes through disproportionation reaction of carbon monoxide over the catalyst. DETAILED DESCRIPTION OF INVENTION
The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
Fig.1 shows a schematic diagram of a reaction apparatus arrangement for generation of single wall carbon nanotubes according to an embodiment of the invention. The reaction apparatus arrangement includes an injector tube 1 having a broad end 1 a and a narrow end 1 b, an injector 3 having a first end 3a, a means for circulation of gas formed on the walls of the injector 3, a hollow chamber 3b for the reaction to occur and a second end 3c and an inner tube 5. The first end 3a of the injector 3 is configured to receive the narrow end 1 b of the injector tube 1 . The diameter of the inner tube 5 is lesser than the diameter of the second end 3c of the injector 3. The difference in the diameter of the inner tube 5 and the injector 3 allows for thermal expansion of the inner tube 1 into the hollow chamber 3b of the injector 3. The reaction apparatus arrangement further includes an outer tube 7, a cylindrical heating element 9, surrounding the outer tube 7 and an insulating jacket 11 covering the cylindrical heating element 11 . The outer tube 7 has an inlet 17 at one end and an outlet 19 at the opposite end. The inlet 17 accommodates injector tube 1 and the outlet 19 accommodates inner tube 5. The narrow end 1 b of the injector tube 1 is detachably attached to the first end 3a of the injector 3. The detachable attachment to the injector 3 is achieved by either push-fit or threaded connection. The injector tube 1 is configured for flow of stream of CO gas along with a catalyst to the injector 3. The stream of CO gas along with the catalyst is maintained at a temperature below the decomposition temperature of the catalyst. The temperature of the stream of CO gas along with the catalyst is maintained at temperature below the decomposition temperature of the catalyst by using cooling methods known in the art such as air cooling or water cooling. In one embodiment of the invention, cooling is achieved by water cooling preferably through circulating water in the injector tube 1 . The catalyst is broadly selected from a group of chemicals such as iron, nickel, cobalt, molybdenum carbonyl, ferrocene. In one embodiment of the invention, the catalyst is iron pentacarbonyl. In another embodiment of the invention, the catalyst is nickel pentacarbonyl. In one embodiment of the invention, the temperature of the stream of CO gas along with the catalyst is maintained at a temperature ranging from 6°C to 100°C. The outlet 19 of the outer tube 7 is connected to a CO gas flow line for counter current flow of CO gas into the outer tube 7. The cylindrical heating element 9 surrounding the outer tube 7 heats the CO gas flowing counter currently in the outer tube to a temperature ranging from 850 - 1200 °C. The heated stream of CO gas is then injected into the injector 3. The injector 3 is configured for mixing of the stream of CO gas along with the catalyst maintained at temperature ranging from 6°C to 100°C with the stream of CO gas maintained at temperature ranging from 850 - 1200 °C.The mixing is achieved through the means for circulation of gas formed on the walls of injector 3 and includes a central hole 13 for flow of stream of CO gas along with the catalyst and a plurality of circumferentially or annular placed holes 15 for flow of the heated stream of CO gas. The mixed stream of gases is injected into the hollow chamber 3b of the injector 3 for reaction to occur. The hollow chamber 3b acts as reaction zone for the generation of single wall carbon nanotubes. The single wall carbon nanotubes are generated through disproportionation reaction of carbon monoxide over the catalyst. The generated single wall carbon nanotubes are then collected by the inner tube 5. The inner tube 5 is a cylindrical tube with the diameter ranging from 6 mm to 20 mm. The length of the inner tube varies from 1000mm to 2500mm. The inner tube is made up of metal alloys including but not limited to alloy of nickel/chromium, alloy of nickel/chromium/molybdenum. Since, the inner tube 5 and the injector 3 is made of metal alloys, during reaction at temperature of 900- 940 °C, the metal alloys tend to expand, the difference in diameter of the inner tube 5 with respect to the injector 3, allows the inner tube 5 to expand inside the hollow chamber 3b of the injector 3. The use of metal alloys and the ability of the inner tube 5 to thermally expand inside the hollow chamber 3b of the injector allow reusability of the inner tube 5 for repeated operations.
The inner tube 5 is configured for receiving the generated single wall carbon nanotubes from the reaction zone of the injector 3. The inner tube 5 is provided with an outlet 21 for continuous removal of the generated single wall carbon nanotubes.
FIG. 2 shows a schematic representation of an injector for generation of single wall carbon nanotubes, according to an embodiment of the invention. The injector 3 is detachably attached to the injector tube 1 and is configured for receiving and mixing atleast two streams of gases at varying temperatures. In one embodiment of the invention, the injector 3 is tubular in shape with an outer diameter ranging from 30-40 mm and inner diameter ranging from 10-30 mm. The length of the injector varies from 30 mm to 100 mm. The injector is made of alloy of metal including but not limited to alloy of nickel/chromium, alloy of nickel/chromium/molybdenum. The injector 3 has a first end 3a, a means for circulation of the gas formed on the walls of the injector, a hollow chamber 3b and a second end 3c. The first end 3a is a closed end and has a centrally placed hole 13. The central hole 13 is configured for flow of stream of CO gas along with the catalyst, preferably iron pentacarbonyl. The temperature of the stream of CO gas along with catalyst is maintained at a temperature below the decomposition temperature of the catalyst. The second end 3c is an open end and is proximal to the inner tube 5. The hollow chamber 3b acts as reaction zone for the generation of single wall carbon nano tubes. The injector 3 is further provided with a plurality of holes 15 placed either circumferentially or on the annular surface of the second end 3c. The plurality of holes 15 are configured for flow of the stream of CO gas maintained at temperature ranging from 850 - 1200 °C into the hollow chamber 3b of the injector 3. In one embodiment of the invention, the plurality of holes 15 are placed on the annular surface of the second end 3c of the injector and run axially along the length of injector 3 and bend at an angle of 90° proximal to the first end 3a to combine with the flow path of central hole 13. In another embodiment of the invention, the plurality of holes 15 are placed on the annular surface of the second end 3c of the injector and run axially along the length of injector 3 and bend at an angle of 45° proximal to the first end 3a to combine with the flow path of central hole 13 to enhance the mixing of the cold and hot stream of CO gas. In yet another embodiment of the invention, the plurality of holes 15 are placed circumferentially on the injector surface towards the first end 3a (Fig 3a). The plurality of holes 15 then run radially and combine with the flow path of central hole 13. In an alternate embodiment of the invention, the plurality of holes 15 are placed circumferentially on the injector surface towards the first end 3a. The plurality of holes 15 then run tangentially and combine with the flow path of central hole 13 (Fig 3b). The hollow chamber 3b acts as a reaction zone, the stream of CO gas along with the catalyst maintained at temperature below the degradation temperature of the catalyst, coming from the central hole 13 mixes with the hot streams of CO gas coming from plurality of holes 15 and generate single wall carbon nano tubes through disproportionation reaction of carbon monoxide over the catalyst.
In an alternate embodiment of the invention, the injector 3 is provided in two parts (Fig. 4a). The first end 3a of the injector is disjoint from the hollow chamber 3b, the first end 3a is connected to the hollow chamber 3b through a threaded connection or a push fit connection. Since the first end 3a of the injector is connected to the injector tube 1 wherein water or air cooling maintains the stream of CO along with catalyst at temperature below the decomposition temperature of the catalyst, the injector is cooler at this end and during the thermal expansion controls the diametrical expansion of the injector and helps in maintaining the gap. In another embodiment of the invention, the injector 3 is provided in three parts (Fig. 4b). The first end 3a of the injector is provided in two parts, a first part (I) and a second part (II). The first part (I) and the second part (II) are connected through a threaded connection or a push-fit connection. The first part (I) is connected to the injector tube 1 and the second part (II) is detachably attached to the hollow chamber 3b through a threaded connection or a push-fit connection. The first part (I) and the second part (II) are made of two different metals or alloys to have control over the diametric expansion due to temperature difference. FIG. 5 shows a flow diagram for generation of single wall carbon nanotubes, according to an embodiment of the invention. Single wall carbon nanotubes are generated in the hollow chamber 3b of the injector by the reaction of CO gas maintained at temperature of 850 °C to 1200 °C with the stream of CO gas along with the catalyst. Formation of uniform diameter, high purity single carbon nanotubes requires, a high reaction temperature in the range of 900 °C to 1000 °C, preferably 950 °C, while the temperature of catalyst to be maintained at a temperature below the decomposition temperature of the catalyst, ranging between 6 °C to 100 °C . The pressure of the reaction apparatus arrangement is maintained at a pressure of 10-50 bars. The pressure of stream of CO gas the injector 3 through plurality of holes 15 is maintained at a pressure of 20-30 bars, while the pressure of stream of CO along with the catalyst is maintained at 15-60 bars. Higher pressure is applied to ensure the continuous forward flow. The pressure in the reaction apparatus arrangement and the lines carrying the streams of CO gas and CO gas along with the catalyst is maintained through a compressor and a set of forward pressure regulators and backward pressure regulators. From the compressor, a high pressure CO gas line (L1 ) at 40-60 bars is divided into two lines L2 (at 15-60 bars) and L3 (at 20-30 bars) through forward pressure regulator. The line L3 maintained at 20-30 bars carrying CO gas enters the reactor through the outlet 19 of the outer tube 7 and gets heated up by the cylindrical heating element to a temperature of 950 °C. The heated stream of CO gas from the outer tube 7 enters the injector 3 through the plurality of holes 15. The line L2 maintained at 15-60 bars carrying CO gas enters a bubbler, where catalyst iron pentacarbonyl is generated and combines with the CO to form the stream of CO gas along with the catalyst. The stream of CO gas along with the catalyst enters the reaction apparatus arrangement through the injector tube 1 and through central hole 13 enters into the injector 3. The injector 3 mixes the hot stream of CO gas with the stream of CO along with the catalyst iron pentacarbonyl. In the hollow chamber 3b of the injector, at high temperature of 950-1000 °C and pressure of 20-30 bars, the iron pentacarbonyl and CO gets atomized. The atomized metal atoms nucleate to form nanoparticles on which the nanotubes grow. Carbon nanotubes are synthesized through reverse Boudouard reaction in the presence of catalyst iron cluster which are formed by the decomposition of iron carbonyl:
Figure imgf000015_0001
The generated single wall carbon nanotubes, byproduct CO2 and unreacted gas leaves the reactor through outlet 21 of the inner tube 5 and passes through various filters. A nanotube filter, removes and collects nanotubes, while a carbon dioxide filter, removes CO2. The unreacted CO gas, through a back pressure regulator is maintained at 16-25 bars and is looped back to the compressor. The single wall carbon nanotubes generated have diameter in the range of 0.8 nm to 1.2 nm with the length ranging 700nm to 1000nm. Characterization:
Characterization of the single walled carbon nanotubes is carried out using Scanning Electron Microscopy(SEM), Raman Spectroscopy, Thermogravimetric analysis(TGA).
FIG. 6 show a TGA plot of single wall carbon nanotube obtained by the reactor, according to an embodiment of the invention. TGA is used to validate SWCNT's purity. The thermogram of the as-prepared materials would show multiple peaks corresponding to various temperatures of decomposition for SWCNT, the oxidation of catalyst particles and decomposition of SWCNT, the oxidation of catalyst particles and decomposition of carbonaceous agglomerates. TGA analysis of graphite, fullerene, and nanotube samples shows that oxidation resistance rises as C-C bonding in nanotubes becomes stronger, since there are fewer dangling bonds that can be oxidized. It is well known that graphite and fullerenes oxidize at maximum rates at 650°C and 420°C, respectively. The active sites for oxidation are found in tube structure defects like open ends, dislocations and missing carbon atoms. The first step in the oxidation reaction's initiation is the presence of pentagons at the ends of the tube, which is a site under strain. The initial weight increase in pristine nanotubes thermogram is not significant because it is less than 1% and can be attributed to the addition of oxygen atoms. Weight decreases as oxidation progresses due to the loss of carbon as CO and CO2. The TGA plot shows that the material contains about 85% of carbon and about 15% of residue (non-carbonaceous impurity). There is no significant weight loss around 100-200°C which indicates very less or no moisture content in the material.
FIG. 7 shows a SEM image of single wall carbon nanotube obtained by the reactor, according to an embodiment of the invention. The SEM image shows nanotubes magnified up to 200,000 times to visualize the bundles of the nanotubes. The SEM image shows fibrous carbon nanotubes with clean tubes and very less amorphous carbon.
FIG. 8 shows a Raman spectrum of single wall carbon nanotube obtained by the reactor, according to an embodiment of the invention. The figure shows Raman spectrum of the single wall carbon nanotube at an excitation wavelength of 514 nm. The presence of a low frequency peak around 200 cm-1 in the Raman spectrum, which corresponds to a SWCNT's radial breathing mode (RBM) and sets it apart from graphite. This RBM characteristic is frequency-measured and is inversely proportional to nanotube radius (r). The D band of the spectrum, which denotes defects or disorder in the structure, corresponds to the peaks, seen around 1340cm-1. The peaks seen between 1550 and 1600 cm-1 are in the G band of the spectrum, which denotes the presence of graphene sheets in the sample and the graphitization of the sample. This G band is divided into the G+ band and the G- band. The G- curve is shaped differently for metallic and semiconducting SWCNTs. The G+ signal indicates vibrational confinement by the tube's circumference. It is a characteristic that is unrelated to tube radius and is dependent on atomic movement in the graphene plane. Given that it originates from the second order harmonic of the D band, the line known as the G' band or 2D band is present around 2650 cm-1. It shows the sample's long-range order. The C=C bond stretching that occurs in all sp2 carbon systems corresponds to the G band in the as-prepared Raman spectrum. The G-band appears to be divided due to the tube's curvature. The G/D ratio of the nanotubes produced is 25.
FIG. 9 shows a UV Vis NIR Spectrum of single wall carbon nanotube obtained by the reactor, according to an embodiment of the invention. The UV Vis NIR Spectrum shows a chirality shift favouring smaller diameter single wall carbon nanotubes.
The invention provides a production technology that produces small diameter, high purity and high quality carbon nanotubes, consumes less energy, is safe and can withstand high temperature and pressure. The arrangement of the present invention can be used for HiPCO process.
The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.

Claims

We Claim:
1. A reaction apparatus arrangement for generation of single wall carbon nanotubes, the arrangement comprising of: an injector tube (1) having a broad end (1a) and a narrow end (1 b); an injector (3) having a first end (3a) wherein the first end (3a) is configured to receive the narrow end (1 b) of the injector tube (1 ), means for circulation of gas formed on the walls of the injector, a hollow chamber (3b) for the reaction to occur and a second end (3c); and an inner tube (5) having a diameter lesser than the diameter of the second end(3c) of the injector.
2. The arrangement as claimed in claim 1 , wherein the arrangement further comprises of an outer tube (7), a cylindrical heating element (9), surrounding the outer tube (7) and an insulating jacket (11) covering the cylindrical heating element (9).
3. The arrangement as claimed in claim 1 , wherein the means for circulation of gas formed on the walls of injector allows for circulation of atleast two streams of gases of varying temperature, wherein one of the atleast two streams of gases is a stream of CO gas along with a catalyst, wherein the other stream of gas is a stream of CO gas.
4. The arrangement as claimed in claim 1 , wherein the injector tube (1 ) is configured for injecting the stream of CO gas along with the catalyst, preferably, iron pentacarbonyl, wherein the stream of CO along with the catalyst is maintained at a temperature below the degradation temperature of the catalyst, wherein the temperature of the stream of CO along with the catalyst is maintained at a temperature ranging from 6°C to 100°C.
5. The arrangement as claimed in claim 1 , wherein the outer tube (7) is configured for counter current flow of CO gas and form the stream of CO gas maintained at a temperature ranging from 850 °C to 1200 °C.
6. The arrangement as claimed in claim 1 , wherein the means for circulation of gas formed on the walls of injector comprises of a central hole (13) for flow of stream of CO gas along with the catalyst and a plurality of circumferentially or annular placed holes (15) for flow of the stream of CO gas.
7. The arrangement as claimed in claim 1 , wherein the hollow chamber of the injector is configured for mixing of the stream of CO maintained at temperature of 850°C to 1200°C and the stream of CO along with the catalyst maintained at a temperature ranging from 6°C to 100°C and generating single wall carbon nanotubes through disproportionation reaction of carbon monoxide over the catalyst.
8. The arrangement as claimed in claim 1 , wherein the outer tube (7) has an inlet (17) at one end for accommodating the injector tube (1) and an outlet (19) at the opposite end for accommodating the inner tube (5).
9. The arrangement as claimed in claim 1 , wherein the difference in diameter between the inner tube (5) and the second end (3c) of the injector allows for thermal expansion of the inner tube (5) into the hollow chamber (3b) of the injector.
10. The arrangement as claimed in claim 1 , wherein the arrangement allows reusability of the inner tube for repeated operations.
11 . The arrangement as claimed in claim 1 , wherein the outer tube has a diameter ranging from 30 mm to 40 mm.
12. The arrangement as claimed in claim 1 , wherein the inner tube has a diameter ranging from 6 mm to 20 mm.
13. The arrangement as claimed in claim 1 , wherein the diameter of the single wall carbon nanotube ranges from 0.8 nm to 1 .2 nm.
14. The arrangement as claimed in claim 1 , wherein the inner tube has an outlet (21 ) for continuous removal of the generated single wall carbon nanotube.
15. The arrangement as claimed in claim 1 , wherein the outer tube 1 and the inner tube 3 is made of alloy of nickel/chromium or alloy of nickel/chromium/molybdenum.
16. The arrangement as claimed in claim 1 , wherein the injector is made of copper, stainless steel or a combination thereof.
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