Effects of hydrogen/carbon molar ratio on graphene nano-flakes synthesis by a non-thermal plasma process

Abstract

Few-layer graphene nano-flakes (GNFs) are successfully prepared via hydrocarbon pyrolysis using a non-thermal plasma process based on a magnetically stabilized gliding arc discharge (MSGAD) at atmospheric pressure. The effects of feedstock gas type and hydrogen flow rate on the morphology of carbon nanomaterials are investigated. When the hydrogen/carbon (H/C) molar ratio is 4, the synthesized GNFs consist of 10 layers per stack with dimensions between 100 and 300 nm in a 4.57.2% yield. The energy cost is 0.1–0.2 kWh/g, which makes this process feasible for large-scale GNFs production. The results show that appropriately increasing the H/C molar ratio promotes the morphological transformation of carbon nanomaterials from spherical carbon nanoparticles (SCNs) to GNFs, improve the quality of GNFs and reduce the stacking of graphite layers. However, increasing the H/C ratio reduces the yields of carbon nanomaterials, so as to increase the energy cost. Analysis suggests that increasing the H/C ratio reduces the concentration of polycyclic aromatic hydrocarbon (PAH) and generates more H atoms, which helps form a two-dimensional nucleation and promotes planar growth. However, an excessive H/C ratio may introduce some defects due to an etching effect.