Liquid-feed
flame spray pyrolysis (LF-FSP) of selected metalloorganics
provides [NiO]0.25[Al2O3]0.75 and [NiO]0.5[Al2O3]0.5 spinel nanopowders (NPs) without aggregation and with good stoichiometric
control. Both compositions were processed to thin films as a first
step in preparing Ni:Al2O3 nanocomposite films
for catalytic synthesis of CNTs. NPs dispersed in polymer were cast
giving 30 ± 10 μm green films that were debindered (370
°C), sintered at 1000–1500 °C/air, and then heated
at 1000–1100 °C in H2/N2 5:95 to
generate Ni particles as catalyst sites. These Ni particles promote
the growth of CNTs. The CNTs were then oxidatively removed coincident
with regeneration of the [NiO]1–x
[Al2O3]
x
surfaces.
Thereafter, reduction, CNT syntheses, and catalyst regeneration were
repeated two times more. The quality and quantity of CNTs were the
same after each cycle. This represents what we believe is a new, general
approach to catalyst recycling/regeneration.