Scalable multiple-inverse diffusion flame burner for synthesis and processing of carbon-based and other nanostructured materials and films and fuels
Apparatus and methods of use thereof for the production of carbon-based and other nanostructures, as well as fuels and reformed products, are provided.
1. A method for the direct synthesis of a carbon-based nanostructure, wherein the carbon-based nanostructure is synthesized by multiple flames produced by reacting an oxidizer and a fuel in a non-premixed, multiple, inverse-diffusion-flame burner,
wherein said carbon-based nanostructure is selected from the group consisting of films, discs, plates, and sheets.
2. The method of claim 1 , wherein said nanostructure is selected from the group consisting of films and sheets.
3. The method of claim 1 , where the non-premixed, multiple, inverse-diffusion-flame burner comprises an array of stabilized flames that form a uniform flat-flame front.
4. The method of claim 1 , where the non-premixed, multiple, inverse-diffusion flames are staged at different levels, or where inert(s), dopant(s), or other reactant(s) are introduced at level(s) different than the first level of stabilized inverse-diffusion flames.
5. The method of claim 1 , wherein the oxidizer is air, O 2 , or another oxidizing agent.
6. The method of claim 1 , wherein the fuel is a hydrocarbon, hydrogen, CO, combustible liquid, combustible solid fuel, or other combustible gas.
7. The method of claim 1 , wherein the carbon-based nanostructure is graphene.
8. The method of claim 1 , wherein the pyrolysis vapors exiting the non-premixed, multiple, inverse-diffusion-flame burner are directed onto substrates or particles to form films and nanostructured coatings and preforms.
9. The method of claim 1 , wherein the pyrolyzed species exiting the non-premixed, multiple, inverse-diffusion-flame burner
a) are quenched to generate said carbon-based nanostructures by a vapor condensation mechanism; or
b) provides heating, levitation, and coating of flat substrates, optionally wherein said substrates can translate and rotate in a continuous coating production mode.
10. The method of claim 1 , further comprising rapid quenching of a hot gas stream comprising pyrolyzed hydrocarbon, thereby generating said carbon-based nanostructure,
wherein said hot gas stream optionally further comprises a reactive species.
11. The method of claim 10 , wherein said reactive species is selected from the group consisting of BH 3 , H 3 NBH 3 , SiH 4 and (CH 3 ) 3 SiH), thereby generating carbon-based nanostructures that are enriched in B, N, Si, or mixtures thereof.
12. The method of claim 1 , where the pyrolysis vapors contain additives, thereby forming doped carbon-based materials.
13. A method of synthesizing molecular hydrogen or a syngas, said method comprising reacting an oxidizer and a fuel in a non-premixed, multiple, inverse-diffusion-flame burner to synthesize said molecular hydrogen or syngas, and isolating the synthesized molecular hydrogen or syngas.
14. The method of claim 13 , wherein said fuel is selected from the group consisting of methane, natural gas, methanol, gasoline, diesel, JP-8, and biofuels.
15. The method of claim 13 , wherein molecular hydrogen is synthesized and said oxidizer is oxygen and said fuel is a hydrocarbon or methane.
16. A flame-deposition reactor comprising a multiple inverse-diffusion flame (IDF) burner,
wherein said IDF burner comprises a reconfigured catalytic converter,
wherein said reconfigured catalytic converter provides separate feed streams for oxidizer and fuel, and
wherein said IDF burner is configured such that the post-flame gas stream is deposited on a non-catalytic, solid or liquid substrate.
17. The flame-deposition reactor of claim 16 , wherein said non-catalytic, solid or liquid substrate is Cu or liquid Sn.
18. The flame-deposition reactor of claim 16 , wherein said non-catalytic, solid or liquid substrate is heated in hydrogen to remove oxides from its surface.
19. A method of synthesizing molecular hydrogen, said method comprising reacting an oxidizer and a fuel in a non-premixed, multiple, inverse-diffusion-flame burner to synthesize said molecular hydrogen, and isolating the synthesized molecular hydrogen.
20. The method of claim 19 , wherein said fuel is a hydrocarbon or methane.