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Utilization of a quasi-pyrolysis chamber (QPC) for synthesizing carbon nanotubes (CNT) in a diffusion flame promises a low-cost and scalable process. However, the flame environment is complex and requires an in-depth understanding of the interrelation of flame and catalyst parameters in optimizing CNT growth in flame using QPC. Hence, this study investigates the effects of vapor catalyst concentration and carrier gas flowrate parameters on the growth rate and morphology of the synthesized CNTs in a QPC via methane diffusion flame. Methane fuel is used as a catalyst carrier gas, with 100% of the fuel flowing through the catalyst nebulizer to the burner outlet. It was observed that a catalyst concentration of 0.05 M obtained the maximum yield of CNTs with minimized bundling and agglomeration. Greater catalyst concentrations enhanced the CNT yield by 20%, but with notable structural irregularities. Lower catalyst concentrations of 0.005 M caused sparse growth due to reduced catalytic activity. In the case of methane flow rates, 0.4 slpm shows the most consistent growth of CNT. A higher flow rate of 0.6 slpm decreased CNT yield by 90%, disrupting flame stability, while a lower flow rate of 0.2 slpm resulted in minimal catalyst carryover into the flame and poor CNT yield. Moreover, modification of the methane flow rate changed the flame structure, extending the flame at excessive flow rates and decreasing temperatures at the chamber inlet, where the majority of CNT growth takes place. The results underscore the necessity to optimize catalyst and methane parameters to achieve high-yield, economical CNT synthesis in advancing flame synthesis as a viable industrial process.

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Experimental Analysis on the Effect of Catalyst Concentration and Fuel Flow Rate Toward Formation of Carbon Nanotubes in Quasi-Pyrolysis Chamber Using Methane Diffusion Flame

  • 会议论文

  • 发表日期：

    2025年

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  • Muhammad Amirrul Amin Moen,
  • Dhevanessh R. Chandraguptha,
  • Mohd Fairus Mohd Yasin,
  • Norikhwan Hamzah

摘要

Utilization of a quasi-pyrolysis chamber (QPC) for synthesizing carbon nanotubes (CNT) in a diffusion flame promises a low-cost and scalable process. However, the flame environment is complex and requires an in-depth understanding of the interrelation of flame and catalyst parameters in optimizing CNT growth in flame using QPC. Hence, this study investigates the effects of vapor catalyst concentration and carrier gas flowrate parameters on the growth rate and morphology of the synthesized CNTs in a QPC via methane diffusion flame. Methane fuel is used as a catalyst carrier gas, with 100% of the fuel flowing through the catalyst nebulizer to the burner outlet. It was observed that a catalyst concentration of 0.05 M obtained the maximum yield of CNTs with minimized bundling and agglomeration. Greater catalyst concentrations enhanced the CNT yield by 20%, but with notable structural irregularities. Lower catalyst concentrations of 0.005 M caused sparse growth due to reduced catalytic activity. In the case of methane flow rates, 0.4 slpm shows the most consistent growth of CNT. A higher flow rate of 0.6 slpm decreased CNT yield by 90%, disrupting flame stability, while a lower flow rate of 0.2 slpm resulted in minimal catalyst carryover into the flame and poor CNT yield. Moreover, modification of the methane flow rate changed the flame structure, extending the flame at excessive flow rates and decreasing temperatures at the chamber inlet, where the majority of CNT growth takes place. The results underscore the necessity to optimize catalyst and methane parameters to achieve high-yield, economical CNT synthesis in advancing flame synthesis as a viable industrial process.