Mass production of multi-wall carbon nanotubes by metal dusting process with high yield

Carbon nanotube materials were synthesized over Fe–Ni nanoparticles generated during disintegration of the surface of alloy 304L under metal dusting environment. The metal dusting condition was simulated and optimized through exposing stainless steel samples during long term repetitive thermal cycling in CO/H2 = 1/1, total gas flow rate 100 cm3/min, at 620 °C for 300 h. After reaction, surface morphology of the samples and also carbonaceous deposition which had grown on sample surfaces were examined by stereoscopy, scanning electron microscopy (SEM) and transmission electron microscopy (TEM). Results revealed that multi-wall carbon nanotubes could be formed over nanocatalyst generated on the alloy surface by exploiting metal dusting process. By optimization of reaction parameters the yields of carbon nanotube materials obtained were 700–1000%. Also it has been shown herein that the amount of carbon nanotube materials remarkably increases when the reaction time is extended up to 300 h, indicating a possibility of the mass production by this easy method.

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► Synthesis of carbon nanotubes over Fe–Ni nanoparticles supported alloy 304L.
► Production of carbon nanotubes with high yield (700–1000%) and low cost catalyst.
► Optimum growth condition is CO/H2 = 1/1, 100 cm3/min, at 620 °C under long term repetitive thermal cycling.
► Possibility of the mass production by metal dusting process with low cost.