Catalyst and process to produce nanocarbon materials in high yield and at high selectivity at reduced reaction temperatures
A carbon nanofiber system is synthesized with very high purity (above 95%), selectivity of the carbon morphology, and exceptionally high yield. A custom made catalyst with a particle size of ≦10 nm and a high surface area (>50 m 2 /g), provides a higher morphological selectivity and higher yield. The reactivity of these catalyst particles is maintained even after 24 hours reaction such that yield exceeds 200 g carbon per gram of catalyst. The catalysts which are key to the products and yields achieved are prepared to specific parameters (size distribution, composition and crystallinity) specified and via a flame synthesis process as taught in U.S. Pat. No. 6,132,653.
1 . A process for producing nanocarbon materials, comprising the following steps:
a. providing a catalyst with a particle size of ≦10 nm and a surface area greater than 50 m2/g;
b. reacting carbonaceous feedstocks in the presence of the catalyst over a given period of time to produce carbon nanofibers with over 99% purity and a morphological selectivity approaching 100% in yields ≧140 g carbon/g catalyst with higher reactivity.
2 . The process in claim 1 , wherein the catalyst is a metal oxide catalyst selected from the metals including iron, nickel, cobalt, lanthanum, gold, silver, molybdenum, iron-nickel, iron-copper and their alloys.
3 . The process in claim 1 , wherein the catalyst is prepared to specific parameters (size distribution, composition and crystallinity) specified and via a flame synthesis process.
4 . The catalyst in claim 1 , wherein the catalyst possesses a single crystal morphology.
5 . The process in claim 1 , wherein the yield of carbon nanomaterial resulted in ≧140 g carbon per g/catalyst.
6 . The process in claim 1 , wherein the morphology of the carbon micro structure can be selectively controlled to achieve various desired orientations in selectivities of ≧90%.
7 . A process for producing nanocarbon materials, comprising the following steps:
a. providing a metal oxide catalyst with a particle size of about ≦10 nm and a surface area greater than 50 m2/g;
b. reacting carbonaceous feedstocks in the presence of the catalyst over a given period of time to produce carbon nanofibers with over 99% purity and a morphological selectivity approaching 100% with yield ≧140 g carbon/g catalyst.
8 . The process in claim 7 , wherein the reaction took place at a temperature not exceeding 550 C.
9 . The process in claim 7 , wherein the purity of carbon nanofibers was >99% after 8 hours reaction time.
10 . The process in claim 7 , wherein the metal oxide catalyst is selected from a group of metals including iron, nickel, cobalt, lanthanum, gold, silver, molybdenum, iron-nickel, iron-copper and their alloys.
11 . Carbon nanofibers of high purity and high reactivity, produced by the steps of:
a. providing a metal oxide catalyst with a particle size of ≦10 nm and a surface area greater than 50 m2/g;
b. reacting carbonaceous feedstocks in the presence of the catalyst over a given period of time to produce the carbon nanofibers with over 99% purity and a selectivity approaching 100% with higher reactivity.
12 . The carbon nanofibers produced by the process in claim 11 , wherein the metal oxide catalyst is selected from a group of metals including iron, nickel, cobalt, lanthanum, gold, silver, molybdenum, iron-nickel, iron-copper and their alloys.
13 . The carbon nanofibers produced by the process in claim 11 , wherein the purity of carbon nanofibers was ≧99% in after 8 hours reaction time.
14 . A carbon nanofiber, of the type produced in the presence of an metal oxide catalyst, the carbon nanofiber comprising at least 99% pure carbon, and produced at high yield, and >90% morphological selectivity.
15 . The carbon nanofiber in claim 14 , wherein the metal oxide catalyst is selected from a group of metals including iron, nickel, cobalt, lanthanum, gold, silver, molybdenum, iron-nickel, iron-copper and their alloys.
16 . A carbon nanofiber composition exhibiting 90% Selectivity to a single morphology as produced.
17 . The composition in claim 16 , wherein the morphology comprises graphene layers oriented parallel to the fiber axis.
18 . The composition in claim 16 , wherein the morphology comprises graphene layers oriented perpendicular to the fiber axis.
19 . The composition of claim 16 , wherein the morphology comprises graphene layers oriented at a specific and equal (±10°) angle to the fiber axis.