Influence of the composition of a H₂-CH₄ gas mixture on the catalytic synthesis of carbon nanotubes-Fe/Fe₃C-Al₂O₃ nanocomposite powders

Abstract

C_NTs-Fe/Fe₃C-Al₂O₃ nanocomposite powders have been prepared by selective reduction of an α-Al_1.9Fe_0.1O₃ solid solution in H₂-CH₄ gas mixtures (0, 1.5, 3, 4.5, 6, 9, 12, 14, 16, 18, 24, 30 and 45 mol% CH₄). The powders have been studied using macroscopic and microscopic techniques. The C_NTs are arranged in very long bundles homogeneously dispersed in the composite powder. Most C_NTs have less than four walls and are free of pyrolytic or amorphous carbon deposits. The inner diameter is in the range 1-6 nm, which could indicate that the catalyst particles active for C_NTs formation are in this size range. The reduction of the Fe³⁺ ions to metallic Fe is highly favoured by the presence of CH₄ in the reduction atmosphere. There are more Fe₃C than α-Fe particles located at the surface of the matrix grains for CH₄ contents higher than 4.5 mol%, however, the exact nature of the catalytically active particles remains an open question. Compositions in the range 9-18 mol% CH₄ give the best results.

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