Method for making single-wall carbon nanotubes using supported catalysts
First Claim
1. A method for producing single-wall carbon nanotubes, comprising:
- (a) providing a supported catalyst of catalytic metal comprising iron (Fe) and molybdenum (Mo) on magnesium oxide (MgO) particles, wherein the catalyst has been prepared by combusting iron, molybdenum and magnesium oxide precursors to form the supported catalyst; and
(b) contacting the catalyst with a gaseous stream comprising a carbon-containing feedstock at a sufficient temperature and for a contact time sufficient to make a carbon product comprising single-wall carbon nanotubes.
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Abstract
A method for growing single-wall carbon nanotubes involves preparing a catalyst comprising catalytic metals, iron and molybdenum, and magnesium oxide support material and contacting the catalyst with a gaseous carbon-containing feedstock at a sufficient temperature and for a sufficient contact time to make single-wall carbon nanotubes. The weight ratio of iron and molybdenum can range from about 2 to 1 to about 10 to 1 and the metals loading up to about 10 wt % of the MgO. The catalyst can be sulfided. Methane is a suitable carbon-containing feedstock. The process can be conducted in batch, continuous or semi-continuous modes, in reactors, such as a transport reactor, fluidized bed reactor, moving bed reactors and combinations thereof. The process also includes making single-wall carbon nanotubes with catalysts comprising at least one Group VIB or Group VIIIB metal on supports such as magnesia, zirconia, silica, and alumina, where the catalyst is sulfided.
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Citations
311 Claims
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1. A method for producing single-wall carbon nanotubes, comprising:
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(a) providing a supported catalyst of catalytic metal comprising iron (Fe) and molybdenum (Mo) on magnesium oxide (MgO) particles, wherein the catalyst has been prepared by combusting iron, molybdenum and magnesium oxide precursors to form the supported catalyst; and
(b) contacting the catalyst with a gaseous stream comprising a carbon-containing feedstock at a sufficient temperature and for a contact time sufficient to make a carbon product comprising single-wall carbon nanotubes. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77)
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78. A method for producing single-wall carbon nanotubes, comprising:
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(a) providing a catalyst of catalytic metal comprising at least one metal from the group consisting of Group VIB and Group VIIIB and a support selected form the group consisting of alumina, magnesia, silica, zirconia and combinations thereof;
(b) sulfiding the catalyst; and
(c) contacting the catalyst with a gaseous stream comprising a carbon-containing feedstock at a sufficient temperature and for a contact time sufficient to make a carbon product comprising single-wall carbon nanotubes. - View Dependent Claims (79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 100, 101, 102, 103, 104, 105, 106, 107, 108, 109, 110, 111, 112, 113, 114, 115, 116, 117, 118, 119, 120, 121, 122, 123, 124, 125, 126, 127, 128, 129, 130, 131, 132, 133, 134, 135, 136, 137, 138, 139, 140, 141, 142, 143, 144, 145, 146, 147, 148, 149)
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150. A method for producing single-wall carbon nanotubes, comprising:
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(a) providing a catalyst of catalytic metal comprising cobalt and molybdenum on magnesium oxide particles;
(b) sulfiding the catalyst; and
(c) contacting the catalyst with a gaseous stream comprising a carbon-containing feedstock at a sufficient temperature and for a contact time sufficient to make a carbon product comprising single-wall carbon nanotubes. - View Dependent Claims (151, 152, 153, 154, 155, 156, 157, 158, 159, 160, 161, 162, 163, 164, 165, 166, 167, 168, 169, 170, 171, 172, 173, 174, 175, 176, 177, 178, 179, 180, 181, 182, 183, 184, 185, 186, 187, 188, 189, 190, 191, 192, 193, 194, 195, 196, 197, 198, 199, 200, 201, 202, 203, 204, 205, 206, 207, 208, 209, 210, 211, 212, 213, 214, 215, 216, 217, 218, 219)
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220. A method for producing single-wall carbon nanotubes, comprising:
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(a) providing a supported catalyst comprising at least one metal from the group consisting of Group VIB and Group VIIIB;
(b) feeding the supported catalyst, a carrier gas, and a carbon-containing feedstock gas to a reactor, wherein the supported catalyst, the carrier gas, and the carbon-containing feedstock gas generally flow through the reactor in substantially the same direction; and
(c) contacting the catalyst with the carbon-containing feedstock in the reactor at a sufficient temperature and for a contact time sufficient to make single-wall carbon nanotubes.
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221. A method for producing single-wall carbon nanotubes, comprising:
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(a) providing a supported catalyst comprising at least one metal from the group consisting of Group VIB and Group VIIIB;
(b) feeding the supported catalyst, a carrier gas, a carbon-containing feedstock gas, and fluidizing aid particles to a fluidized bed reactor;
(c) contacting the catalyst with the carbon-containing feedstock in the reactor at a sufficient temperature and for a contact time sufficient to make single-wall carbon nanotubes;
(d) withdrawing an upper product stream from the reactor that comprises single-wall carbon nanotubes; and
(e) separately withdrawing a lower product stream from the reactor that comprises fluidizing aid particles. - View Dependent Claims (222, 223)
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224. A method for producing single-wall carbon nanotubes, comprising:
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(a) providing a supported catalyst comprising at least one metal from the group consisting of Group VIB and Group VIIIB;
(b) continuously feeding the supported catalyst, a carrier gas, a carbon-containing feedstock gas, and fluidizing aid particles to a reactor, wherein the fluidizing aid particles flow generally counter-current to the carrier gas and carbon-containing feedstock gas in the reactor;
(c) contacting the catalyst with the carbon-containing feedstock in the reactor at a sufficient temperature and for a contact time sufficient to make single-wall carbon nanotubes;
(d) withdrawing an upper product stream from the reactor that comprises single-wall carbon nanotubes; and
(e) separately withdrawing a lower product stream from the reactor that comprises fluidizing aid particles. - View Dependent Claims (225, 226)
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227. A method for producing single-wall carbon nanotubes, comprising:
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(a) providing a supported catalyst comprising at least one metal from the group consisting of Group VIB and Group VIIIB;
(b) continuously feeding the supported catalyst, a carrier gas, a carbon-containing feedstock gas, and fluidizing aid particles to a reactor, wherein the fluidizing aid particles generally flow in substantially the same direction as the carrier gas and carbon-containing feedstock gas in the reactor;
(c) contacting the catalyst with the carbon-containing feedstock in the reactor at a sufficient temperature and for a contact time sufficient to make single-wall carbon nanotubes;
(d) withdrawing an product stream from the reactor that comprises single-wall carbon nanotubes, and fluidizing aid particles; and
(e) separating the single-wall carbon nanotubes from the fluidizing aid particles. - View Dependent Claims (228, 229)
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230. A method for producing carbon nanotubes, comprising:
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(a) providing a supported catalyst comprising refractory particles and at least one or more catalytic metal selected from the group consisting of Group VIIIB, Group VIB and combinations thereof; and
(b) contacting the catalyst with a gaseous stream comprising a carbon-containing feedstock at a sufficient temperature and for a contact time sufficient to make a carbon product comprising carbon nanotubes. - View Dependent Claims (231, 232, 233, 234, 235, 236, 237, 238, 239, 240, 241, 242, 243, 244, 245, 246, 247, 248, 249, 250, 251, 252, 253, 254, 255, 256, 257, 258, 259, 260, 261, 262, 263, 264, 265, 266, 267, 268, 269, 270, 271, 272, 273, 274, 275, 276, 277, 278, 279, 280, 281, 282, 283, 284, 285, 286, 287, 288, 289, 290, 291, 292, 293, 294, 295, 296, 297, 298, 299, 300, 301, 302, 303, 304, 305, 306, 307, 308, 309, 310, 311)
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Specification