Carbon fibers are produced by pyrolysis of natural gas inside stainless steel tubes. Lengthening of unthickened precursor carbon filaments is normally catalyzed by loose metal or carbide particles generated in situ, primarily by fragmentation of the growth tube wall. More direct methods of supplying a greater number of catalytic particles were investigated in an effort to increase fiber yield. Growth of fibers on the inner surface of steel tubes could be enhanced by either: 1. 1) local melting of the surface in the presence of air, or 2. 2) wetting the surface with an aqueous ferric nitrate solution. Both methods increased the number of carbon fibers produced per unit area about 20-fold over as-received stainless steel tubes. Scanning electron microscopy and X-ray diffraction analyses showed that both procedures left the growth substrates covered with a rough, relatively thick layer comprised of a mixture of iron oxides. Precipitation of iron during reduction of the oxide mass is an important mechanism for providing an abundance of particles which catalyze carbon filament growth.
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