Large scale combustion synthesis of single-walled carbon nanotubes and their characterization.

Since its invention in 1991, premixed combustion synthesis of fullerenic materials has been established as the major industrial process for manufacturing of these materials. Large-scale production of fullerenes such as C60, C70 and C84 has been implemented. More recently, combustion technology has been extended to the targeted synthesis of single-walled carbon nanotubes (SWCNT). Addition of catalyst precursor and operation at well-controlled fuel-rich but non-sooting conditions are required. Extensive parametric studies have allowed for the optimization of the formation of high-quality SWCNT. Purification techniques previously reported in the literature have been adjusted and used successfully for the nearly complete removal of metal and metal oxide. Material has been characterized using Raman spectroscopy, scanning (SEM) and transmission electron microscopy (TEM), scanning transmission electron microscopy (STEM), atomic force microscopy (AFM), X-ray diffraction (XRD), and thermogravimetric analysis (TGA). Correlations between process conditions and nanotube properties such as length have been established. Product reproducibility and process scalability of the combustion process have been demonstrated. Sample preparation was found to affect significantly the apparent characteristics of nanotubes as seen in electron microscopy images.

Carbon nanotube formation and growth via particle-particle interaction.

Carbon nanotubes are observed to form under a wide range of temperatures, pressures, reactive agents, and catalyst metals. In this paper we attempt to rationalize this body of observations reported in the literature in terms of fundamental processes driving nanotube formation. Many of the observed effects can be attributed to the interaction of three key processes: surface catalysis and deposition of carbon, diffusive transport of carbon, and precipitation effects. A new nanotube formation mechanism is proposed that describes the nanotube structures observed experimentally in a premixed flame and can account for certain shortcomings of the prevailing mechanism that has been repeatedly applied to explain nanotube formation in nonflame environments. The interacting particle model (IPM) attributes the initiation of nanotube growth to the physical interaction between catalyst particles. Coalescence of two (or more) catalyst particles leads to partial blocking of the particle surface, causing a disparity in carbon deposition over the particle surface. The resulting concentration gradient generates a net diffusive flux toward the interparticle contact point. Dimers that separate in this condition can support continuous nanotube growth between the particles. The model can also be extended to multiple particles to account for more complex morphologies. The IPM is consistent with many of the structures observed in the flame-produced material. The validity of the model is evaluated through analysis of diffusion dynamics and a force analysis of particle binding and separation. The IPM is also discussed in relation to identifying the requirements and best conditions to support nanotube growth in the premixed flame. The formation of nanotubes between particles as described by the IPM indicates that a single mechanism cannot completely describe nanotube synthesis; more likely, multiple pathways exist with varying rates that depend on specific process conditions.

Effects of temperature and soil components on emissions from pyrolysis of pyrene-contaminated soil.

Effects of temperature and soil on yields and identities of light gases (H2, CH4, C2H2, C2H4, C2H6, CO, and CO2) and polycyclic aromatic hydrocarbons (PAH) from thermal treatment of a pyrene-contaminated (5 wt%) soil in the absence of oxygen were determined for a U.S. EPA synthetic soil matrix prepared to proxy U.S. Superfund soils. Shallow piles (140-170 mg) of contaminated soil particles and as controls, neat (non-contaminated) soil (140-160 mg), neat pyrene (10-15 mg), neat sand (230 mg), and pyrene-contaminated sand (160 mg), were heated in a ceramic boat inside a 1.65 cm i.d. pyrex tube at temperatures from 500 to 1100 degrees C under an axial flow of helium. Volatile products spent 0.2-0.4s at temperature before cooling. Light gases, PAH and a dichloromethane extract of the residue in the ceramic boat, were analyzed by gas chromatography or high pressure liquid chromatography (HPLC). Over 99% pyrene removal was observed when heating for a few tens of seconds in all investigated cases, i.e., at 500, 650, 750, 1000, and 1100 degrees C for soil, and 750 and 1000 degrees C for sand. However, each of these experiments gave significant yields (0.2-16 wt% of the initial pyrene) of other PAH, e.g., cyclopenta[cd]pyrene (CPP), which mutates bacterial cells and human cells in vitro. Heating pyrene-polluted soil gave pyrene conversions and yields of acetylene, CPP, and other PAH exceeding those predicted from similar, but separate heating of neat soil and neat pyrene. Up to 750 degrees C, recovered pyrene, other PAH, and light gases accounted for all or most of the initial pyrene whereas at 1000 and 1100 degrees C conversion to soot was significant. A kinetic analysis disentangled effects of soil-pyrene interactions and vapor phase pyrolysis of pyrene. Increase of residence time was found to be the main reason for the enhanced conversion of pyrene in the case of the presence of a solid soil or sand matrix. Light gas species released due to the thermal treatment, such as acetylene and methane, lead the formation of other, pyrene-derived PAH, e.g., methylpyrenes, cyclopenta[cd]pyrene, and benzo[a]pyrene. Implications of these findings for the chemistry of soil thermal decontamination and for diagnosing potential defects in soil thermal cleaning, e.g., incomplete elimination of targeted pollutants and formation of adverse by-products, are discussed.

A study on toxic organic emissions from batch combustion of styrene.

Results from a laboratory-scale investigation on batch combustion of styrene are reported herein. Limited quantities of waste styrene monomer are incinerated, however this monomer is, also, the primary pyrolyzate during combustion of waste polystyrene, the second most abundant polymer produced worldwide. Thus, its combustion-generated emissions are of importance to the operation of hazardous waste incinerators and municipal waste-to-energy powerplants. This work focuses on emissions of polycyclic aromatic hydrocarbons (PAHs), particulates, as well as carbon monoxide. To investigate methods for minimizing such emissions, batch combustion of the monomer was conducted in a two-stage muffle furnace. An additional air mixing chamber was installed between the two stages. Small quantities of the liquid monomer were inserted in the primary furnace which served as a gasifier/burner. The furnace temperature was in the range of 300-1000 degrees C and diffusion flames were formed under most conditions. Upon mixing with additional air, combustion of unburned gaseous fuel and primary reaction products continued in the secondary furnace (afterburner), which was kept at a constant temperature of either 1000 or 800 degrees C. Using this technique, conditions that minimize emissions were explored and theoretical investigations on the fate of pollutants in the secondary furnace were undertaken. Results revealed that combustion of styrene, which is a highly volatile fuel, occurred with the formation of flames that were often non-anchored, unsteady and unstable. Emissions of organic pollutants, soot and CO were more intense than in the case of the polystyrene combustion, studied previously under identical conditions, due to the additional depolymerization/pyrolysis steps therein. The emissions from the secondary furnace exceeded those of the primary furnace, consistent with the fact that a very significant fraction of the fuel conversion occurred in the secondary chamber. Clear trends in the emissions of PAHs and soot, products of incomplete combustion, with the temperature of the primary furnace (gasifier) were observed. Emissions were drastically reduced with lowering the gasifier temperature. While final cumulative emissions of PAHs and soot accounted for more than one third of the mass of the fuel at high temperatures, their concentrations at the exit of the afterburner were negligible when the primary furnace was operated at 300 degrees C under pyrolytic conditions. In the latter case air was added to the afterburner. Numerical modeling based on a complex reaction network was used for the description of the primary furnace as well as of the afterburner. Kinetic analysis showed acetylene and benzene to be key species in the growth of PAHs. Formation of PAHs in the afterburner, found experimentally, was reproduced by the model using a plug-flow assumption.

Polynuclear aromatic hydrocarbon and particulate emissions from two-stage combustion of polystyrene: the effects of the secondary furnace (afterburner) temperature and soot filtration.

Laboratory experiments were conducted in a two-stage horizontal muffle furnace in order to monitor emissions from batch combustion of polystyrene (PS) and identify conditions that minimize them. PS is a dominant component of municipal and hospital waste streams. Bench-scale combustion of small samples (0.5 g) of shredded styrofoam cups was conducted in air, using an electrically heated horizontal muffle furnace, kept at Tgas = 1000 degrees C. Upon devolatilization, combustion of the polymer took place in a diffusion flame over the sample. The gaseous combustion products were mixed with additional air in a venturi and were channeled to a secondary muffle furnace (afterburner) kept at Tgas = 900-1100 degrees C; residence time therein varied between 0.6 and 0.8 s. At the exits of the primary and the secondary furnace the emissions of CO, CO2, O2, NOx, particulates as well as volatile and semivolatile hydrocarbons, such as polycyclic aromatic hydrocarbons (PAH), were monitored. Online analyzers, gravimetric techniques, and gas chromatography coupled to mass spectrometry (GC-MS) were used. Experiments were also conducted with a high-temperature barrier filter, placed just before the exit of the primary furnace to prevent the particulates from entering into the secondary furnace. Results demonstrated the beneficial effect of the afterburner in reducing PAH concentrations, including those of mutagenic species such as benzo[a]pyrene. Concentrations of individual PAH exhibited a pronounced after burner temperature dependence, typically ranging from a small decrease at 900 degrees C to a larger degree of consumption at 1100 degrees C. Consumption of PAH was observed to be the dominant feature at 900 degrees C, while significant quantities of benzene and some of its derivatives, captured by means of carbosieve/Carbotrap adsorbents, were formed in the afterburner at a temperature of 1000 degrees C. In the primary furnace, about 30% of the mass of the initial polystyrene was converted into soot, while the total mass of PAH represented about 3% of the initial mass of combustible. The afterburner reduced the particulate (soot) emissions by only 20-30%, which indicates that once soot is formed its destruction is rather difficult because its oxidation kinetics are slow undertypical furnace conditions. Moreover, increasing the afterburnertemperature resulted in an increasing trend of soot emissions therefrom, which might indicate competition between soot oxidation and formation, with some additional formation occurring at the higher temperatures. Contrary to the limited effect of the afterburner, high-temperature filtration of the combustion effluent prior to the exit of the primary furnace allowed for effective soot oxidation inside of the ceramic filter. Filtration drastically reduced soot emissions, by more than 90%. Limited soot formation in the afterburner was again observed with increasing temperatures. The yields of both CO and CO2 were largely unaffected by the temperature of the afterburner but increased at the presence of the filter indicating oxidation therein. A previously developed kinetic model was used to identify major chemical reaction pathways involving PAH in the afterburner. The experimental data at the exit of the primary furnace was used as input to these model computations. A first evaluation of the predictive capability of the model was conducted for the case with ceramic filter and a temperature of 900 degrees C. The afterburner was approximated as a plug-flow reactor, and model predictions at a residence time of 0.8 s were compared to experimental data collected at its exit. In agreement with the experimental PAH concentration, only a minor impact of the afterburner treatment was observed for most species at 900 degrees C. OH was deduced to be the major reactant with a mole fraction about 4 orders of magnitudes higher than that of hydrogen radicals. Evidence for the need of further work on the quantitative assessment of oxidation of PAH and their radicals is given.