Carbon nanotubes (CNTs) are a promising material for
sensors and
composites, where the addition of chemical functional groups enables
selective binding or dispersion. Common functionalization processes
often require refluxing in nitric acid (HNO3), resulting
in poor control while adding safety, cost, and environmental burdens.
Using CNTs grown from acetylene, methylacetylene, or vinylacetylene,
we examined a vapor-based functionalization technique with hydrochloric
acid (HCl), aiming to reduce morphological damage and material and
energy consumption. HNO3 enabled increased oxygen addition
via liquid versus vapor treatments (1.6–2.2% vs 0.88–1.0%),
while HCl preferably added chlorine via vapor treatments (0.05–0.1%
vs 0.02–0.03%). Interestingly, liquid HCl treatments yielded
1.2–2.2% oxygen, and for vinylacetylene-derived CNTs, the oxygen
addition was greater than a HNO3-treated sample (2.2 ±
1.5 vs 1.6 ± 0.4%), providing important mechanistic insights
for the growth of CNTs and subsequent oxygen addition reaction pathways
at defect loci. Life cycle impact assessment demonstrated that using
HCl reduced global warming potential and ecotoxicity (98 and 92% reductions,
respectively) compared to HNO3. Vapor treatments offered
additional improvements, primarily via elimination of electric heating
required for reflux. These results demonstrate the importance of structure
in CNT substitution and the potential for HCl- and vapor-based treatments
for soft CNT functionalization with reduced environmental impact.