Catalytic composition for synthesizing carbon nanotubes

Abstract

The present invention relates to a catalytic composition for the synthesis of carbon nanotubes, comprising an active catalyst and a catalytic support, the active catalyst comprising a mixture of iron and cobalt in any oxidation form and the catalytic support comprising exfoliated vermiculite.

Claims

1. A catalytic composition for the synthesis of carbon nanotubes comprising an active catalyst and a catalytic support, the active catalyst comprising a mixture of iron and cobalt in any oxidation form and the catalytic support comprising exfoliated vermiculite.

2. The catalytic composition according to claim 1, characterized in that the molar proportion of cobalt and iron (Co/Fe) is comprised between 0.1 and 2.

3. The catalytic composition according to claim 2, characterized in that the molar proportion of cobalt and iron (Co/Fe) is comprised between 0.25 and 1.5.

4. The catalytic composition according to claim 1, characterized in that the weight percentage of the active catalyst relatively to the catalytic composition is comprised between 1.5 and 20%.

5. The catalytic composition according to claim 4, characterized in that the weight percentage of the active catalyst relatively to the catalytic composition is comprised between 2.2 and 12%.

6. The catalytic composition according to claim 4, characterized in that the weight percentage of the active catalyst relatively to the catalytic composition is comprised between 2.2 and 8%.

7. The catalytic composition according to claim 1, characterized in that the exfoliated vermiculite has a particle size comprised between 50 and 1,000 μm.

8. The catalytic composition according to claim 7, characterized in that the exfoliated vermiculite has a particle size comprised between 100 and 500 μm.

9. A method for synthesizing the catalytic composition according to claim 1 comprising the following steps: Exfoliation of the vermiculite by treatment of a vermiculite ore at a temperature above 800° C.; Contacting the exfoliated vermiculite with a solution of a cobalt and iron salt; Calcination of the vermiculite contacted with a solution of a cobalt and iron salt at a temperature above 350° C.

10. The synthesis method according to claim 9, characterized in that the iron salt is Fe(NO).sub.3.9H.sub.2O.

11. The synthesis method according to claim 9, characterized in that the cobalt salt is Co(OAc).sub.2.4H.sub.2O.

12. The synthesis method according to claim 9, characterized in that contacting the exfoliated vermiculite with a solution of a cobalt and iron salt is accomplished by impregnation with an aqueous solution.

13. A method for synthesizing carbon nanotubes by decomposing a gaseous hydrocarbon on a catalytic composition according to claim 1, comprising the following steps: Conditioning the catalytic composition under an inert atmosphere; Contacting the catalytic composition with a gaseous carbon source at a temperature between 600 and 800° C. for at least 5 minutes.

14. The method for synthesizing carbon nanotubes according to claim 13, characterized in that the supply of catalytic composition and the extraction of synthesized carbon nanotubes is continuous.

Description

SHORT DESCRIPTION OF THE FIGURES

(1) FIG. 1 shows the influence of the water impregnation volume on the yield of the catalytic composition while keeping the molar ratio Co/Fe and the metal percentage constant.

(2) FIG. 2 shows the influence of the Co/Fe ratio on the yield of the catalyst. A series of 10 catalysts was prepared while keeping a level of 4% of metals.

(3) FIG. 3 shows the influence of the percentage of metals on the yield of the catalyst.

(4) FIG. 4 shows the influence of the synthesis time on the yield of the catalyst (a plateau is reached after 25 minutes).

(5) FIG. 5 shows the influence of the vermiculite type on the yield of the catalyst.

(6) FIG. 6 shows the influence of the type of solvent used for dissolving the metal salts on the yield of the catalyst.

(7) FIG. 7 shows the bulk resistivity of a polycarbonate composite (Makrolon 2205-Bayer) using different concentrations of carbon nanotubes obtained by various synthesis methods comprising the carbon nanotubes obtained by catalytic synthesis on a vermiculite support according to the invention.

(8) FIG. 8 shows the surface resistivity of a polycarbonate composite comprising different concentrations of carbon nanotubes obtained by various synthesis methods including the carbon nanotubes obtained by catalytic synthesis on a vermiculite support according to the invention.

(9) FIG. 9 shows the surface resistivity and FIG. 10 shows the bulk resistivity of a polysiloxane composite (VQM 809+ crosslinker 100+ Catalyst 510+ inhibitor 600− Hanse Chemie) comprising different concentrations of the carbon nanotubes obtained by various synthesis methods including the carbon nanotubes obtained by catalytic synthesis on a vermiculite support according to the invention.

(10) FIG. 11 shows the surface resistivity of a composite of an epoxy resin (Epikote 828− Hexion) comprising different concentrations of carbon nanotubes obtained by various synthesis methods comprising the carbon nanotubes obtained by catalytic synthesis on a vermiculite support according to the invention.

DETAILED DESCRIPTION OF THE INVENTION

(11) The invention consists in producing a catalytic composition with an active catalyst and a catalytic support, the active catalyst comprising a mixture of cobalt and iron on a catalytic support comprising exfoliated vermiculite. This catalytic composition allows to obtain carbon nanotubes which, when they are dispersed in polymeric matrices, provide a high electric conductivity level with low concentrations of carbon nanotubes. The invention also describes a method for the synthesis of the catalytic composition.

(12) The method for preparing the catalytic composition comprises the following steps: Exfoliation of the vermiculite by treatment of a vermiculite ore at a temperature above 800° C.; Impregnation of the exfoliated vermiculite with a solution of a cobalt and iron salt. Calcination of the impregnated vermiculite under an inert atmosphere at a temperature above 350° C.

Example of Synthesis of the Catalytic Composition

(13) 1) Exfoliation of the vermiculite by treatment of a vermiculite ore (Imerys, Shawa mine Zimbabwe) at 900° C. for 2 minutes under nitrogen and then letting it cool down to room temperature. 2) Preparation of a solution of metal salts: 1.14 g of Fe(NO.sub.3).sub.3.9H.sub.2O and 0.35 g of Co(OAc).sub.2.4H.sub.2O are weighed, and then dissolved in 10 ml of water. 3) Impregnation: The solution is poured into 6 g of exfoliated vermiculite. Mixing is performed with a spatula for homogenization. Impregnation is left to act for about 1 night. 4) Drying/calcination: The mixture is calcined under nitrogen according to a temperature program consisting of a rapid rise in temperature up to 400° C., followed by a plateau for 1 hour and then by cooling.

Example of Synthesis of Carbon Nanotubes

(14) 1) 1 g of catalyst is weighed and then scattered on a container. 2) The container is placed in the cold area of the reactor. The plug of the quartz tube is placed and a flow of 2 l/min of nitrogen is let through for 6 mins. 3) A nitrogen, ethylene and hydrogen mixture is let through with flows of 0.857 l/min, 1.744 l/min and 0.286 l/min respectively. One waits for 6 mins so that the concentrations in the reactor stabilize. 4) The container is introduced into the hot area of the reactor, adjusted beforehand to 700° C. It is left to react for 20 mins. 5) The gases are stopped and a flow of 2 l/min of nitrogen is introduced. The container is placed in the cold area. The container is left to cool for 6 mins. The plug is opened and the nanotubes are collected.

(15) After having synthesized the carbon nanotubes by means of the catalytic composition according to the invention, the latter are dispersed by conventional means into various polymeric matrices.

Example of Dispersion of Carbon Nanotubes in a Polycarbonate Matrix

(16) 12.5 g mixtures are prepared containing 0.75%, 1%, 1.5%, 2%, 3%, 4% respectively by mass fraction of carbon nanotubes in a polycarbonate matrix PC2205.

(17) The different mixtures are passed into a co-rotary twin-screw micro-extruder of the 15 cm.sup.3 DSM Xplore type. Mixing is performed at 280° C., at 50 rpm for 5 minutes. The molten mixture is then injected with a micro-injector of the 12 cm.sup.3 DSM Xplore type, the piston chamber of which is heated to 280° C. and the mold to 100° C. The injection is achieved with a pressure of 8 bars for 2 seconds, followed by a rise up to 12 bars within 8 seconds and finally 12 bars are maintained for 4 seconds. The mold is a 2-bar IZOD mold.

(18) The ends of the bars are sawed over 3 mm.

(19) Silver paint is applied on the ends of the bars and the 2-point measurement of bulk resistivity is carried out with a multimeter of the Keithley 2700 type.

(20) Silver paint is applied in 2 strips separated by 1 cm and the 2-point measurement of surface resistivity is carried out with a multimeter of the Keithley 2700 type. The results of these measurements are illustrated in FIGS. 7 to 11.

(21) Influence of Different Parameters on the Yield of the Catalytic Composition According to the Invention

EXAMPLES

(22) A) The Co/Fe ratio

(23) FIG. 2 shows different Co/Fe ratios. Maximum productivity is reached with a ratio of about 0.5 to 0.66.

(24) Preparation Conditions

(25) TABLE-US-00001 Support Metals Impregnation calcination 6 g Imerys Vermiculite, Shawa Fe(NO.sub.3).sub.3•9H.sub.2O Water 400° C. Mine Zimbabwe, Micron Co(OAc).sub.2•4H.sub.2O volume: 8 ml 1 h Sifted (>500 μm) Variable Co/Fe molar ratio Rest: 16 h 1 m.sup.3/h N.sub.2 Exfoliated for 2 mins at 900° C. Mass % of metal = 4.0% under 2 l/min of N.sub.2
Results

(26) TABLE-US-00002 Mass of Mass of Co/Fe Yield Catalyst Co(OAc).sub.2•4H.sub.2O Fe(NO.sub.3).sub.3•9H.sub.2O molar ratio (g/g) 137 0.35 1.14 1/2 11.7 138 0.26 1.28 1/3 7.9 139 0.53 0.86 1/1 10.7 185 0.63 0.69 3/2 5.04 143 0.42 1.03 2/3 11.7 144 0.48 0.94 5/6 10.9 177 0.34 0.28 2/1 3.7 178 0.11 0.69 1/4 6.5 235 0.1 1.57  1/10 3.99 193 0 1.74 0/1 2.0

(27) B) Percentage of Metal in the Catalytic Composition

(28) Three series of catalysts were prepared. The series with the constant ratio Co/Fe=0.333 and Co/Fe=1.5 comprises 4 points. The series with the constant ratio Co/Fe=0.5 comprises 9 points. The curves of FIG. 3 show that a metal percentage around 5% gives the best yield in the catalytic composition regardless of the Co/Fe ratio.

(29) Preparation Conditions

(30) TABLE-US-00003 Support Metal Impregnation calcination 6 g Imerys Vermiculite, Fe(NO.sub.3).sub.3•9H.sub.2O Water 400° C. Shawa Mine Zimbabwe, Co(OAc).sub.2•4H.sub.2O volume: 8 ml 1 h Micron Co/Fe molar ratio: Rest: 16 h 1 m.sup.3/h N.sub.2 Sifted (>500 μm) 0.33; 0.5 and 1.5 Exfoliated for 2 mins at Mass % of metal = 900° C. under 2 l/min of variable from N.sub.2 0.74 to 20.
Results

(31) TABLE-US-00004 Mass % Co/Fe Mass of Mass of of molar Yield Catalyst Co(OAc).sub.2•4H.sub.2O Fe(NO.sub.3).sub.3•9H.sub.2O metal ratio (g/g) 146 0.064 0.21 0.74 0.5 0.64 195 0.086 0.284 1 0.5 1.2 194 0.132 0.426 1.5 0.5 4.31 142 0.19 0.62 2.2 0.5 9 137 0.35 1.14 4 0.5 11.7 141 0.51 1.66 5.8 0.5 12.1 182 0.7 2.274 8 0.5 10.9 183 1.052 3.41 12 0.5 9.3 196 1.752 5.682 20 0.5 5.31 184 0.31 0.336 2 1.5 1.72 185 0.622 0.672 4 1.5 5.04 186 0.932 1.008 6 1.5 5.13 187 1.864 2.016 12 1.5 3.07 234 3.10 3.66 20 1.54 2.76 188 0.132 0.642 2 0.33 7.01 189 0.264 1.284 4 0.33 9.26 190 0.396 1.926 6 0.33 9.24 191 0.792 3.854 12 0.33 7.44 233 1.32 6.42 20 0.33 3.74

(32) C) The Vermiculite Type

(33) A series of 3 catalysts was prepared from 3 vermiculites of different origin. The Imerys and Nestaan vermiculites were thermally exfoliated at about 900° C. under nitrogen. Sifting was also required for removing the impurities (>500 μm). The results show that the origin of the vermiculite has little influence on the yield of the catalyst.

(34) Preparation conditions

(35) TABLE-US-00005 Metals Impregnation calcination 1.14 g Fe(NO.sub.3).sub.3•9H.sub.2O Water 400° C. 0.35 g Co(OAc).sub.2•4H.sub.2O volume: 5 ml 1 h Fe/Co molar ratio = 2/1 Rest: 16 h 1 m.sup.3/h N.sub.2 Mass % of metal = 4.0%
Results

(36) TABLE-US-00006 Yield Catalyst Provider Grade Origin Preparation (g/g) 173 Imerys M8 Mud tank sifted (>500 μm), 9.7 (Australia) exfoliated at 900° C. under N.sub.2 137 Imerys Micron Shawa mine sifted (>500 μm), 11.7 (Zimbabwe) exfoliated at 900° C. under N.sub.2 169 Nestaan Micron (China) Already exfoliated 10.5

(37) D) Synthesis Time

(38) In FIG. 4, it is clearly shown that after 25 minutes a yield plateau is reached.

(39) Preparation Conditions

(40) TABLE-US-00007 Support Metals Impregnation calcination 6 g Imerys 1.03 g Fe(NO.sub.3).sub.3•9H.sub.2O Water volume: 400° C. Vermiculite, 0.42 g Co(OAc).sub.2•4H.sub.2O 8 ml 1 h Shawa Mine Co/Fe molar ratio: Rest: 16 h 1 m.sup.3/h N.sub.2 Zimbabwe, 0.66 Micron Sifted Mass % of metal = 4.0% (>500 μm) Exfoliated for 2 mins at 900° C. under 2 l/min de N.sub.2
Results

(41) TABLE-US-00008 Synthesis Catalyst time (min) Yield (g/g) 143 10 7.13 15 9.61 20 11.69 25 11.98

(42) E) Influence of the Type of Solvents

(43) 5 catalysts were prepared from 5 different solvents. The vermiculite used is the one from Australia.

(44) Preparation conditions

(45) TABLE-US-00009 Support Metals Impregnation calcination 6 g Imerys Vermiculite, Mud 1.14 g Fe(NO.sub.3).sub.3•9H.sub.2O Solvent volume: 400° C. Tank Mine (Australia) 0.35 g Co(OAc).sub.2•4H.sub.2O 5 ml 1 h Sifted (>500 μm) Fe/Co molar ratio = Rest: 16 h 1 m.sup.3/h N.sub.2 Exfoliated for 2 mins at 2/1 900° C. under 2 l/min of N.sub.2 Mass % of metal = 4.0%
Results

(46) TABLE-US-00010 Catalyst Solvent Yield (g/g) 173 Water 9.7 174 Acetone 8.37 200 Ethylene glycol 3.37 231 Ethanol 2.94 232 Methanol 3.58

(47) The results show that the solvent has an influence on the yield of the catalyst. Although water in this specific case is the best solvent, an organic solvent such as acetone may also give a high-yield catalyst.

(48) Furthermore, an additional catalyst was prepared with 1.14 g of Fe(NO.sub.3).sub.3.9H.sub.2O and 0.41 g of Co(NO.sub.3).sub.2.6H.sub.2O (Co/Fe ratio=0.5) in 5 ml of acetone. The latter gave a yield of 5.83 g/g. This shows that a good solvent-salts combination may sometimes be necessary for having a high-yield catalyst.

(49) F) The Water Impregnation Volume

(50) In order to determine the limit between an impregnation and a suspension method, different volumes of water were tested (see FIG. 1).

(51) Preparation Conditions for the Catalytic Composition

(52) TABLE-US-00011 Support Metals Impregnation calcination 6 g Imerys Vermiculite, 1.14 g of Fe(NO.sub.3).sub.3•9H.sub.2O Water volume: 400° C. Shawa Mine Zimbabwe, 0.35 g of Co(OAc).sub.2•4H.sub.2O variable from 4 to 30 ml 1 h Micron, sifted (>500 μm) Fe/Co molar ratio = 2/1 Rest: 16 h 1 m.sup.3/h N.sub.2 Exfoliated for 2 mins at Mass % of metal = 4.0% 900° C. under 2 l/min of N.sub.2
Results

(53) TABLE-US-00012 Catalyst Water No. volume (ml) Yield (g/g) 114 10 9.2 134 8 11.3 135 12 10.1 137 5 11.7 138 8 7.9 145 4 11.0 179 15 8.3 180 20 7.6 181 30 7.6

(54) The impregnation may be considered as <<dry>> when the water volume is less than 10 ml for 6 g of vermiculite. Beyond this volume, the vermiculite is immersed in the metal solution and during drying, a deposition of metals may occur on the walls of the container. This loss of metals is expressed by a reduction in the yield. The water volume threshold may however depend on the grain size of the vermiculite used.

(55) Method by Filtration as Compared with the Method by Infiltration

(56) A series of 4 catalysts was also prepared by the method of the articles of Zhang et al. i.e. by suspension-filtration, by using the best metal salts (Fe(NO.sub.3).sub.3.9H.sub.2O and Co(OAc).sub.2.4H.sub.2O) and the best Co/Fe ratio (1/2).

(57) Preparation Conditions

(58) 6 g of Nestaan micron vermiculite are placed in an Erlenmeyer. Water and a magnetic stirrer are added therein. The mixture is stirred at 80° C. for 6 hours in order to generate a suspension. An aqueous solution of Fe(NO.sub.3).9H.sub.2O and of Co(OAc).sub.2.4H.sub.2O is added therein. The mixture is filtered by means of a frit in vacuo. The obtained paste is calcined at 400° C. under nitrogen for 1 hour. 2 volumes of water as well as 2 amounts of metal salts are used.

(59) TABLE-US-00013 Yield Mass of metal salts H.sub.2O (ml) (g/g) 1.14 g Fe(NO.sub.3).sub.3•9H.sub.2O + 0.35 g Co(OAc).sub.2•4H.sub.2O 50 1.0 1.14 g Fe(NO.sub.3).sub.3•9H.sub.2O + 0.35 g Co(OAc).sub.2•4H.sub.2O 100 0.16 4.54 g Fe(NO.sub.3).sub.3•9H.sub.2O + 1.40 g Co(OAc).sub.2•4H.sub.2O 50 11.9 4.54 g Fe(NO.sub.3).sub.3•9H.sub.2O + 1.40 g Co(OAc).sub.2•4H.sub.2O 100 7.2

(60) It can be seen that this preparation method may give rise to active catalysts with high yield provided that sufficiently concentrated metal solutions are available, nevertheless it shows a few difficulties as compared with the method by dry impregnation: the level of metals deposited on the vermiculite is difficult to control, it depends on the filtration quality; the preparation time is very long, notably for suspension and filtration; this method requires a larger amount of metal salts, a good portion is lost in the filtrate.