Carbon nanotubes (CNTs) are an allotrope of carbon with unique properties that make them potentially useful in a vast range of applications. However, CNTs are predominantly produced using expensive and/or nonrecyclable catalyst supports, e.g., mesoporous silica and alumina. In this work, coal combustion fly ash, a bulk waste product with limited uses, was impregnated with iron nitrate and successfully used as a substrate to produce industrial grade multiwalled carbon nanotubes (MWNTs) by fluidized bed chemical vapor deposition. CNTs were analyzed using thermogravimetric analysis, Raman spectroscopy, scanning electron microscopy and transmission electron microscopy. The most successful catalyst trialed at 650 degrees C using ethylene as a carbon source was a 5 wt % Fe fly ash catalyst, which produced a CNT yield in respect to metal loading of approximately 82.5%. The MWNTs had outer diameters of between 12 and 20 nm with a reasonable degree of wall graphitization (I(G)/I(D) of 1.17). Advantages of utilizing fly ash as a catalyst support are its availability at low cost at the megaton scale, its high thermal stability, and suitability for use in industrial fluidized bed reactors. Potential applications for the fly ash produced CNTs include use in composite materials.

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The interaction effects between temperature, catalyst properties, fluidization conditions, and deposition time during carbon nanotube (CNT) synthesis by chemical vapor deposition in a fluidized bed were investigated. While numerous investigations have attempted to correlate process parameters with CNT characteristics, selectivity and yield, the interaction between process parameters is often ignored. Parametric interactions in this process have been investigated using a factorial design methodology. Besides the main effects of synthesis temperature, deposition time, and catalyst type, the interaction parameters temperature−time and temperature−catalyst were found to significantly influence the resultant carbon and CNT yields. These results lay the foundation for a detailed parametric analysis toward the optimization of CNT synthesis in fluidized beds, which takes into account these interaction effects.

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