Decomposition of metal carbides as an elementary step of carbon nanotube synthesis

The role of catalyst components in catalysts containing molybdenum, Mo/M/MgO (MNi, Co, and Fe), as well as Mo-free catalysts, M/MgO (MNi, Co, and Fe), for carbon nanotube (CNT) synthesis have been investigated by TEM, XRD, and Raman spectroscopy. CNT synthesis by the catalytic decomposition of CH4 over M/MgO catalysts can proceed at reaction temperatures higher than the decomposition temperature of the metal carbides (Ni3C, Co2C, and Fe3C), which indicates that carbon in the CNT originates from the graphitic carbon formed on the catalyst surface by the decomposition of metal carbides. For all catalysts containing Mo, thin CNT formation starts at an identical temperature of 923 K, corresponding to the decomposition temperature of MoC1−x into Mo2C. The significant effect of the addition of Mo is concerned with the formation of Mo2C in a catalyst particle during CNT synthesis at high reaction temperatures. The presence of a stable Mo2C phase leads to the formation of thin CNT with better crystallinity at high reaction temperatures. The role of Ni, Co, and Fe in the Mo/M/MgO catalysts is ascribed to the dissociation of CH4.