New continuous gas-phase synthesis of high purity carbon nanotubes by a thermal plasma jet

Abstract

We have developed a new gas-phase synthesis technique to produce carbon nanotubes (CNTs) with a continuous process and at high temperature, by using a thermal plasma jet. A thermal plasma jet was generated by applying a direct current of 100–300 A, using Ar as the plasma gas with a flow rate of ∼6 ksccm. The temperature of the thermal plasma jet was very high (∼10 4 K) and the velocity was very fast (∼100 m/s). Fe(CO) 5 and CO were used as a catalyst precursor and carbon source, respectively. The yield of CNTs was dramatically increased by attaching a helical extension reactor at the end of the plasma nozzle. High purity (∼80%) CNTs were produced with a continuous process by using a thermal plasma jet with helical extension reactor equipment. The number of CNT walls produced was critically affected by the hydrogen gas injected as an auxiliary plasma gas. Without hydrogen gas, single-walled carbon nanotubes whose diameter was about 1 nm were mostly produced while with hydrogen gas double-walled carbon nanotubes (about 4 nm in diameter) were predominantly produced, with small amount of 3- and 4-walled carbon nanotubes.