Virginia Gomeza,
Silvia Irustab,
Olawale B. Lawalc,
Wade Adamsc,
Robert H. Hauge*cd,
Charles W. Dunnill*a and
Andrew R. Barron*acd
aEnergy Safety Research Institute (ESRI), College of Engineering, Swansea University, Bay Campus, SA1 8EN, Swansea, Wales, UK. E-mail: C.Dunnill@swansea.ac.uk; a.r.barron@swansea.ac.uk; arb@rice.edu
bDepartment of Chemical Engineering, Aragon Institute of Nanoscience (INA), University of Zaragoza, Zaragoza, 50018, Spain
cDepartment of Materials Science and Nanoengineering, Rice University, Houston, TX 77005, USA. E-mail: hauge@rice.edu
dDepartment of Chemistry, Rice University, Houston, TX 77005, USA
First published on 22nd January 2016
A new two-step purification method of carbon nanotubes (CNTs) involving a microwave treatment followed by a gas-phase chlorination process is reported. The significant advantage of this method over conventional cleaning carbon nanotubes procedures is that under microwave treatment in air, the carbon shells that encase the residual metal catalyst particles are removed and the metallic iron is exposed and subsequently oxidized making it accessible for chemical removal. The products from microwave and chlorine treatment have been characterized by TG/DTA, SEM, TEM, EDX, XPS, and Raman spectroscopy. The oxidation state of the iron residue is observed to change from Fe(0) to Fe(II)/Fe(III) after microwave treatment and atmospheric exposure. The effects of the duration and number of microwave exposures has been investigated. This rapid and effective microwave step favours the subsequent chlorination treatment enabling a more effective cleaning procedure to take place, yielding higher purity single- and multi-walled CNTs.
Carbon nanotube purification methods can be divided in two main groups: physical and chemical. Generally physical purification complex methods involve processes like size exclusion chromatography, microfiltration, centrifugation and high temperature annealing among others.6–9 These methods preserve the structure of the carbon nanotubes but are not 100% effective in removing the impurities. Chemical purification methods commonly use gas-phase10 and wet methods.11–13 Liquid-phase oxidation is effective in removing both, amorphous carbon and metallic catalyst particles but often require the use of strong oxidants like HNO3,12,13 a mixture of H2SO4:HNO3 and KMNO4. Many of the oxidation routes result in the graphitic surface of the carbon nanotubes becoming functionalized with oxygen-containing groups leading to issues further down the line with the application of the CNTs.14 Another problem is that transition metal catalysts can remain encapsulated affecting the performance of the carbon nanotubes in many practical applications. Non-oxidative acid treatments with HCl have been also been employed to purify CNTs. Recently, we have observed that catalyst nanoparticles can be efficiently removed from carbon nanotubes using a high temperature chlorination process.5 In this treatment, metal catalyst residues are treated with Cl2 gas to create halides that vaporises at high temperature. This has the advantages of both the physical and chemical methods, eliminating the carbon and a great amount of the catalytic residues present. It is however unable to eliminate the catalytic particles that remain encased by either graphitic or amorphous carbon.
Rapid heating and decreased sintering temperatures make microwave energy more efficient than conventional heating processes in several applications. We have been interested in the applications in chemical synthesis15–20 and processing of new materials.21,22 Microwave energy has been also used in purification and functionalization methods of carbon nanotubes.23–25 Microwave treatment has proven to improve the thermal stability, mechanical properties and electrical conductivity of multi-walled carbon nanotubes (MWCNTs).23 Microwave irradiation leads to rapid temperature increase in carbon nanotubes.26 The microwave absorbing properties of carbon nanotubes can be affected by several factors as their geometrical characteristics, chemistry composition, etc. In addition, iron nanoparticles present in raw nanotubes have been shown to improve microwave absorbing properties,27 however, their role in microwave absorption is still not clear. Recently, microwaves were used as a purification method of aligned arrays of single-walled carbon nanotubes (SWCNTs).25 Wu and Mitra have developed a microwave-based method to remove the oxidation debris from carbon nanotubes.24
In this work a new two-step physico-chemical cleaning method for carbon nanotubes has been developed. The carbon nanotubes are first microwaved in air and then treated using Cl2 gas at high temperature. The combined effect of both treatments reduces the amount of iron catalyst in the samples with a very small degree of oxidation of the nanotubes surfaces, liberating the iron particles during the first stage (microwave treatment) and increasing the effectiveness of the subsequent chlorinating step. The purity and quality of the samples throughout the different purification steps has been studied by thermogravimetric analysis, Raman spectroscopy, scanning electron microscopy, scanning transmission electron microscopy and X-ray photoelectron spectroscopy.
Sample name | Description |
---|---|
MWCNTs | Multi-walled carbon nanotubes |
MWCNTs/MWx | Microwave treated multi-walled carbon nanotubes with x = number of treatments |
MWCNTs/MWx/Cl2 | Microwave and chlorinated treated multi-walled carbon nanotubes with x = number of treatments |
SWCNTs | Single-walled carbon nanotubes |
SWCNTs/MWx | Microwave treated single-walled carbon nanotubes with x = number of treatments |
SWCNTs/MWx/Cl2 | Microwave and chlorinated treated single-walled carbon nanotubes with x = number of treatments |
As can be seen in Table 2, the MWCNTs used in the present study have a significantly higher iron content than the HiPCO SWCNTs studied. Under microwave, light discharge (light) processes can be observed in both the samples, and in the case of the MWCNTs visible orange areas related with the oxidation of the iron are observed.30
Sample | C | O | Fe |
---|---|---|---|
a Each analysis is expressed as the average of four analysis areas. | |||
MWCNTs | 81 ± 4 | 1 ± 1 | 17 ± 4 |
MWCNTs/MW1 | 34 ± 18 | 21 ± 5 | 43 ± 13 |
SWCNTs | 79 ± 5 | 9 ± 1 | 6 ± 2 |
SWCNTs/MW1 | 74 ± 1 | 13 ± 3 | 7 ± 3 |
Fig. 3 compares SEM micrographs of original multiwall carbon nanotubes before and after being microwaved. After a microwave treatment (Fig. 3c and d) SEM micrographs showed a clear change in contrast and shape in the samples. While the MWCNTs appear intact (Fig. 3c) as confirmed by Raman spectroscopy and TEM, the amorphous carbon that was ingrained between the tubes has been removed. In contrast, areas of amorphous particulates appear in other regions of the same sample (Fig. 3d) consistent with the formation of iron oxide. Presumably, this latter region had higher catalysts content than that observed in Fig. 3c.
The EDX elemental analysis of MWCNTs versus MWCNTs/MW1 (Table 2) shows an increase in the iron and oxygen weight percentage with a concomitant decrease in the carbon content after a microwave treatment. This result suggests that microwave treatments lead to carbon loss. In order to confirm this result, three samples of MWCNTs (10 mg each) were treated several times under microwaves and weighed after each treatment. As Fig. 4 shows, the total weight loses after this treatment was around 12 ± 4%. We note that even though the samples came from the same growth batch of MWCNTs, the magnitude of the decrease is variable depending on the sample, indicating the general inhomogeneity of the sample. This decrease in weight is explained by the conversion of amorphous carbon into CO2 during the microwave treatment in agreement with.30
The samples were studied by XPS in order to assess the iron state in each of the steps of the purifying process. XPS analysis showed spectral bands attributed to Fe 2p3/2, O 1s, C 1s and Cl 2p3/2 levels. Table 3 shows the atomic percentage of XPS results, which are in general agreement with the EDX data (Table 2), i.e., after microwave treatment the carbon content decreases with an increase in both iron (6×) and oxygen (1.84×). The final Fe:O ratio (0.782) is close to that of Fe3O4 (0.75) suggesting the predominant formation of an oxide. More informative is provided from the high-resolution Fe 2p spectra (Fig. 5) on the relative oxidation states of the iron (Table 4).
Sample | Binding energy/eV (atomic%) | |||
---|---|---|---|---|
C 1s | O 1s | Fe 2p3/2 | Cl 2p3/2 | |
MWCNTs | 284 | 531 | 710 | — |
(96.9%) | (2.5%) | (0.6%) | ||
MWCNTs/MW10 | 284 | 530 | 711 | — |
(91.8%) | (4.6%) | 3.6% | ||
MWCNTs/MW10/Cl2 | 284 | 530 | 711 | 200 |
(91.6%) | (5.9%) | 2.3% | 0.2% | |
SWCNTs | 284 | 532 | 707 | — |
(94.5%) | (4.2%) | 1.3% | ||
SWCNTs/MW10 | 284 | 530 | 710 | — |
(68.8%) | (21.7%) | 9.5% | ||
SWCNTs/MW10/Cl2 | 284 | 532 | 711 | — |
(92.0%) | (6.6%) | 1.4% |
Fig. 5 High resolution XPS of the Fe 2p3/2 peak of (a) MWCNTs and (b) MWCNTs/MW10 showing the different iron oxidation states. |
Samples | Fe 2p3/2 binding energy (eV) (atomic%) | ||
---|---|---|---|
Fe0 | Fe2+ | Fe3+ | |
MWCNTs | 707.2 (12%) | 710.2 (44%) | 711.8 (44%) |
MWCNTs/MW10 | 707.2 (4%) | 710.1 (32%) | 711.4 (64%) |
MWCNTs/MW10/Cl2 | — | 710.0 (36%) | 711.8 (64%) |
SWCNTs | 707.0 (45%) | 709.8 (55%) | — |
SWCNTs/MW10 | 707.3 (18%) | 709.9 (30%) | 711.4 (52%) |
In the raw MWCNTs the iron is present as both Fe0 and oxidized forms (Table 4 and Fig. 5). Upon microwave treatment the zero valent iron is decreased to only 4% and the residue is mostly a mixture of Fe2+ and Fe3+,31–33 which is the relative composition (Fe2+:Fe3+ = 0.5) to that of Fe3O4 (0.5). This result suggest that the elemental iron that is encapsulated within a carbon shell (and therefore not oxidized under ambient conditions) is exposed to air upon the microwave irradiation, presumably as a result of the amorphous carbon shell being pyrolyzed (see Fig. 1).
Further confirmation of the processes occurring during microwave irradiation is provided by TG/DTA, see Table 5. As may be seen from the TGA of MWCNTs upon multiple microwave treatments (Fig. 6a) the onset temperature and final decomposition temperature are shifted to higher values when the nanotubes have been microwaved under air. Gradual onset (as observed for MWCNTs) is believed to be due to the presence of amorphous carbon and other types of carbonaceous impurities that oxidize at temperatures lower than that of nanotubes. The shift in the onset is thus explained being due to the removal of the amorphous carbonaceous compounds during microwave treatment, and hence the purification of the sample. The weight gain observed at around 450 °C in the untreated samples is due the formation of metal oxide from the incompletely oxidized catalyst (Fig. 6a inset). After multiple microwave treatments, all the iron catalyst is oxidised and the curve remains flat. The largest exothermic peak in the differential thermal analysis (DTA) curves (Fig. 6b) indicates the initial combustion of amorphous carbon and subsequent combustion of MWCNTs. It can be seen that this peak is shifted to higher temperatures and becomes narrower and sharper after microwave treatment under air. This again highlights the reduction in the amount of amorphous carbon in the samples. The remaining residue observed after the MWCNTs analysis by TGA in air (Fig. 7a) is mostly comprised of iron oxide (Fig. 7b).
Sample | Oxidation temp. (°C) | Onset point (°C) | Wt% loss @ 200 °C | Wt% loss 300–800 °C | Residue @ 800 °C |
---|---|---|---|---|---|
MWCNTs | 579 | 528 | 1% | 82% | 18% |
MWCNTs/MW5 | 616 | 557 | 1% | 87% | 12% |
MWCNTs/MW10 | 662 | 575 | 1% | 99% | 1% |
SWCNTs | 440 | 356 | 6% | 77% | 12% |
SWCNTs/MW5 | 482 | 434 | 4% | 58% | 32% |
SWCNTs/MW10 | 518 | 454 | 9% | 62% | 22% |
Fig. 6 Thermogravimetric (a) and differential thermal analysis (DTA) (b) analysis of MWCNTs before and after microwave treatments. |
Fig. 7 SEM micrographs and EDX analysis spectra of the residues of MWCNT after TGA analysis under air leaving only iron oxides. |
The behaviour of SWCNTs upon microwave irradiation is analogous to that of the MWCNTs. The EDX shows that the analysis is essentially unchanged after a single microwave treatment (Table 2); however, both the amorphous carbon content and the iron content are significantly lower in HiPCO SWCNTs than other raw materials. The more surface sensitive XPS does the same type of increase in iron and oxygen with a decrease in carbon content (Table 3) as observed with MWCNTs. The Fe:O ratio is changed from 0.31 in the raw sample to 0.43 after microwave treatment for 10 min: a ratio that is still too iron rich in comparison to oxygen to be purely oxide. This is supported by the analysis of the high-resolution.
Fe 2p signal that shows the amount of Fe0 is reduced upon microwave irradiation, but not eliminated (Fig. 8 and Table 4). However, unlike the MWCNTs the iron in the as-produced SWCNTs is limited to Fe0 and Fe2+,31–33 suggesting that almost all the catalyst residue is encapsulated rather than exposed to the environment. Thus, the presence of Fe3+ after microwave treatment indicates that much of the encapsulate has been removed allowing the Fe0 to be oxidized to Fe3+.
Fig. 8 High resolution Fe 2p3/2 XPS spectra of (a) SWCNTs and (b) SWCNTs/MW10 showing of the oxidation state of the iron. |
More detailed information of the differences between SWCNTs and MWCNTs is obtained from the TG/DTA (Table 5). As may be seen from the TGA of SWCNTs upon multiple microwave treatments (Fig. 9a) the onset temperature is shifted to higher values when the nanotubes have been microwaved under air; due to the removal of the amorphous carbonaceous compounds. After multiple microwave treatments the final mass increases and then decreases. As with MWCNTs the largest exothermic peak in the differential thermal analysis (DTA) curves for SWCNTs (Fig. 9b) is shifted to higher temperatures; however this is most probably associated with the removal of surface functionality (such as epoxides) that are inherent in as-prepared HiPCO SWCNTs.
Fig. 9 Thermogravimetric (a) and differential thermal analysis (DTA) (b) analysis of SWCNTs before and after microwave treatments. |
Overall, SWCNTs show a lower level of improvement from microwave treatment as compared to MWCNTs; however, this may be due to the generally higher level of purity of the as-synthesized material. In each case the microwave appears to expose Fe0 residue to enable its oxidation to Fe2+ or Fe3+. We have previously reported that reaction of SWCNTs with Cl2 gas results in the removal of exposed iron,5 but that it appeared not to be useful for encapsulated iron. Given the effects of the microwave treatment, a combination approach should significantly decrease the iron content.
As Table 3 shows, the atomic percentage of iron increases after microwaving the MWCNTs and then, after the chlorine treatment, is reduced again. Although the absolute amount of iron is increased as compared to as-synthesized MWCNTs, the overall purity of the sample is improved with the removal of amorphous carbon and an estimated 36% of the iron catalyst residue. Interestingly, the high-resolution Fe 2p spectra (Table 4) indicate that the relative ratio of Fe2+ to Fe3+ is not altered by the chlorine treatment, even though the overall iron content decreases. This suggests that there is no differentiation between the reaction of the oxidation states, and that either insufficient reaction time is allowed or the remaining iron is trapped within the MWCNTs themselves. The former has some support since a small amount of chlorine is observed indicative of residual FeCl3 that has not sublimed. With regard to the latter, high-resolution TEM micrographs of treated MWCNTs (Fig. 10) show the presence of catalyst nanoparticles as brighter areas due to the high Fe atomic number. These particles are present in the as-synthesized MWCNTs both at the surface (red arrows) and inside them (blue arrows). After microwave and chlorine treatment the only nanoparticles observed appear to be encapsulated within the CNTs (Fig. 10b and c). Thus, it appears that during the first step of the purification, nanoparticle envelopes are “opened” and the iron is oxidized. The lack of catalyst particles residing on the surface of the MWCNTs is particularly important for uses in biological and medical applications.35 However, the question remains as to whether the microwave/Cl2 treatment damages the nanotube structure (Table 6).
Sample | IG/ID |
---|---|
MWCNTs | 5.0 |
MWCNTs/MW10 | 4.5 |
MWCNTs/MW10/Cl2 | 3.0 |
SWCNTs | 12.4 |
SWCNTs/MW10 | 31.7 |
SWCNTs/MW10/Cl2 | 19.1 |
The Raman spectra of raw and treated MWCNTs are shown in Fig. 11. As is typical, three characteristics bands are observed, namely the D-band at ∼1348 cm−1, the G-band at ∼1572 cm−1 and the D′-band at ∼1610 cm−1. The D-band is usually related to the presence of amorphous or disordered carbon in the samples, such as graphitic planes or defects on the nanotube walls, vacancies, heptagon–pentagon pairs, kinks and heteroatoms.36 It is a disorder induce feature related to the double resonance Raman scattering process.37–39 The G band is created by the in/plane tangential stretching of the carbon–carbon bonds in grapheme sheets. The D′ band which appears as a G-band shoulder is also induced by disorders and defects. As may be seen from the IG/ID ratio in Table 5 there is little change between the raw MWCNTs, microwave treatment (i.e., MWCNTs/MW10), and the two-step process (i.e., MWCNTs/MW10/Cl2). This suggests that the combined process dramatically reduced the iron content along with the amorphous carbon, but does not significantly alter the structure of the MWCNTs themselves.
In this work, the microwave treatment of as-prepared MWCNTs allows an extra exposure and the oxidation of the metallic particles protected by amorphous or graphitic layers. These particles are therefore easily removed by a subsequent Cl2 treatment improving the effectiveness of this cleaning process and reducing the iron content in the nanotubes as shown in Table 4. The combined effect of the microwave and the chlorination treatment is more important in the case of the SWCNTs where the percentage of Fe0 is higher (Table 4) and the size of the catalyst particles is also smaller making their removal more difficult as can be seen in Fig. 12a. From the TEM images it is observed that while iron-based nanoparticles are still present after microwave and chlorine treatment (i.e., SWCNTs/MW10/Cl2) the number appears to have diminished (Fig. 12b) consistent with the XPS data (Table 4).
The Raman spectra of raw and treated SWCNTs are shown in Fig. 13. Unlike the MWCNTs, the IG/ID ratio of the SWCNTs (Table 5) is dramatically increases upon microwave treatment consistent with the removal of surface functionality40 and possible annealing.7 There is, however, a subsequent slight decrease upon chlorination, although the value is still higher than the as-prepared SWCNTs.
This journal is © The Royal Society of Chemistry 2016 |