Synthesis of Ni-Cu-CNF Composite Materials via Carbon Erosion of Ni-Cu Bulk Alloys Prepared by Mechanochemical Alloying

The unique physical and chemical properties of composite materials based on carbon nanofibers (CNFs) makes them attractive to scientists and manufacturers. One promising method to produce CNFs is catalytic chemical vapor deposition (CCVD). In the present work, a method based on carbon erosion (CE) of bulk microdispersed Ni-Cu alloys has been proposed to prepare efficient catalysts for the synthesis of CNF-based composites. The initial Ni-Cu alloys were obtained by mechanochemical alloying (MCA) of metallic powders in a planetary mill. The effect of MCA duration on the phase composition of Ni-Cu samples was studied by X-ray diffraction analysis and temperature-programmed reduction in hydrogen. It has been also revealed that, during such stages as heating, reduction, and short-term exposure to the reaction mixture (C2H4/H2/Ar) at 550 °C, the formation of a Ni-based solid solution from the initial Ni-Cu alloys takes place. The early stages of the CE process were monitored by transmission electron microscopy combined with energy-dispersive X-Ray analysis. It was found that the composition of the catalytic particles is identical to that of the initial alloy. The morphological and structural features of the prepared Ni-Cu-CNF composites were studied by scanning and transmission electron microscopies. The textural characteristics of the composites were found to be dependent on the reaction time

Experimental and Simulation Study on Coproduction of Hydrogen and Carbon Nanomaterials by Catalytic Decomposition of Methane-Hydrogen Mixtures

Among all hydrocarbons, the methane molecule contains the highest amount of hydrogen with respect to carbon. Therefore, the catalytic decomposition of methane is considered as an efficient approach to produce hydrogen along with nanostructured carbon product. On the other hand, the presence of hydrogen in the composition of the initial gas mixture is required for the stable operation of the catalyst. In present work, the experiments on the catalytic decomposition of methane–hydrogen mixture were performed in a flow-through quartz reactor equipped with McBain balances under atmospheric pressure. The catalyst NiO-CuO/Al2O3 was prepared by the mechanochemical activation technique. The maximum carbon yield of 34.9 g/gcat was obtained after 2 h of experiment at 610 °C. An excess of hydrogen in the reaction mixture provided the long-term activity of the nickel–copper catalyst. The durability tests ongoing for 6 h within a temperature range of 525–600 °C showed no noticeable deactivation of the catalyst. Two kinetic models, D1a and M1a, were proposed for the studied decomposition of the methane–hydrogen mixture over the nickel–copper catalyst. The kinetic constants for these models were determined by means of mathematical modelling

Experimental and Simulation Study on Coproduction of Hydrogen and Carbon Nanomaterials by Catalytic Decomposition of Methane-Hydrogen Mixtures

Among all hydrocarbons, the methane molecule contains the highest amount of hydrogen with respect to carbon. Therefore, the catalytic decomposition of methane is considered as an efficient approach to produce hydrogen along with nanostructured carbon product. On the other hand, the presence of hydrogen in the composition of the initial gas mixture is required for the stable operation of the catalyst. In present work, the experiments on the catalytic decomposition of methane–hydrogen mixture were performed in a flow-through quartz reactor equipped with McBain balances under atmospheric pressure. The catalyst NiO-CuO/Al2O3 was prepared by the mechanochemical activation technique. The maximum carbon yield of 34.9 g/gcat was obtained after 2 h of experiment at 610 °C. An excess of hydrogen in the reaction mixture provided the long-term activity of the nickel–copper catalyst. The durability tests ongoing for 6 h within a temperature range of 525–600 °C showed no noticeable deactivation of the catalyst. Two kinetic models, D1a and M1a, were proposed for the studied decomposition of the methane–hydrogen mixture over the nickel–copper catalyst. The kinetic constants for these models were determined by means of mathematical modelling

Comparative Study on Carbon Erosion of Nickel Alloys in the Presence of Organic Compounds under Various Reaction Conditions

The processes of carbon erosion of nickel alloys during the catalytic pyrolysis of organic compounds with the formation of carbon nanofibers in a flow-through reactor as well as under reaction conditions in a close volume (Reactions under Autogenic Pressure at Elevated Temperature, RAPET) were studied. The efficiency of the ferromagnetic resonance method to monitor the appearance of catalytically active nickel particles in these processes has been shown. As found, the interaction of bulk Ni-Cr alloy with the reaction medium containing halogenated hydrocarbons (1,2-dichloroethane, 1-iodobutane, 1-bromobutane) results in the appearance of ferromagnetic particles of similar dimensions (~200–300 nm). In the cases of hexachlorobenzene and hexafluorobenzene, the presence of a hydrogen source (hexamethylbenzene) in the reaction mixture was shown to be highly required. The microdispersed samples of Ni-Cu and Ni-Mo alloys were prepared by mechanochemical alloying of powders and by reductive thermolysis of salts-precursors, accordingly. Their interaction with polymers (polyethylene and polyvinyl chloride) under RAPET conditions and with ethylene and 1,2-dichloroethane in a flow-through reactor are comparatively studied as well. According to microscopic data, the morphology of the formed carbon nanofibers is affected by the alloy composition and by the nature of the used organic substrate

Effect of Cu on Performance of Self-Dispersing Ni-Catalyst in Production of Carbon Nanofibers from Ethylene

The development of effective catalysts for the pyrolysis of light hydrocarbons with the production of carbon nanomaterials represents a relevant direction. In the present work, the influence of copper addition on performance of a self-dispersed Ni-catalyst and structural features of the obtained carbon nanofibers (CNFs) was studied. The precursors of Ni and Ni-Cu catalysts were prepared by activation of metal powders in a planetary mill. During contact with the C2H4/H2 reaction mixture, a rapid disintegration of the catalysts with the formation of active particles catalyzing the growth of CNFs has occurred. The kinetics of CNF accumulation during ethylene decomposition on Ni- and Ni-Cu catalysts was studied. The effect of temperature on catalytic performance was explored and it was shown that introduction of copper promotes 1.5–2-fold increase in CNFs yield in the range of 525–600 °C; the maximum CNFs yield (100 g/gcat and above, for 30-min reaction) is reached on Ni-Cu-catalyst at 575–600 °C. A comparative analysis of the morphology and structure of CNF was carried out using electron microscopy methods. The growth mechanism of carbon filaments in the shape of “railway crossties” on large nickel crystals (d > 250 nm) was proposed. It was found that the addition of copper leads to a decrease in the bulk density of the carbon product from 40–60 to 25–30 g/L (at T = 550–600 °C). According to the low-temperature nitrogen adsorption data, specific surface area (SSA) of CNF samples (at T 2/g, regardless of the catalyst composition; at T = 600 °C the introduction of copper contributed to an increase in the specific surface of CNF by 100 m2/g

Selected Aspects of Hydrogen Production via Catalytic Decomposition of Hydrocarbons

Owing to the high hydrogen content, hydrocarbons are considered as an alternative source for hydrogen energy purposes. Complete decomposition of hydrocarbons results in the formation of gaseous hydrogen and solid carbonaceous by-product. The process is complicated by the methane formation reaction when the released hydrogen interacts with the formed carbon deposits. The present study is focused on the effects of the reaction mixture composition. Variations in the inlet hydrogen and methane concentrations were found to influence the carbon product’s morphology and the hydrogen production efficiency. The catalyst containing NiO (82 wt%), CuO (13 wt%), and Al2O3 (5 wt%) was prepared via a mechanochemical activating procedure. Kinetics of the catalytic process of hydrocarbons decomposition was studied using a reactor equipped with McBain balances. The effects of the process parameters were explored in a tubular quartz reactor with chromatographic analysis of the outlet gaseous products. In the latter case, the catalyst was loaded piecemeal. The texture and morphology of the produced carbon deposits were investigated by nitrogen adsorption and electron microscopy techniques

Efficient Production of Segmented Carbon Nanofibers via Catalytic Decomposition of Trichloroethylene over Ni-W Catalyst

The catalytic utilization of chlorine-organic wastes remains of extreme importance from an ecological point of view. Depending on the molecular structure of the chlorine-substituted hydrocarbon (presence of unsaturated bonds, intermolecular chlorine-to-hydrogen ratio), the features of its catalytic decomposition can be significantly different. Often, 1,2-dichloroethane is used as a model substrate. In the present work, the catalytic decomposition of trichloroethylene (C2HCl3) over microdispersed 100Ni and 96Ni-4W with the formation of carbon nanofibers (CNF) was studied. Catalysts were obtained by a co-precipitation of complex salts followed by reductive thermolysis. The disintegration of the initial bulk alloy driven by its interaction with the reaction mixture C2HCl3/H2/Ar entails the formation of submicron active particles. It has been established that the optimal activity of the pristine Ni catalyst and the 96Ni-4W alloy is provided in temperature ranges of 500–650 °C and 475–725 °C, respectively. The maximum yield of CNF for 2 h of reaction was 63 g/gcat for 100Ni and 112 g/gcat for 96Ni-4W catalyst. Longevity tests showed that nickel undergoes fast deactivation (after 3 h), whereas the 96Ni-4W catalyst remains active for 7 h of interaction. The effects of the catalyst’s composition and the reaction temperature upon the structural and morphological characteristics of synthesized carbon nanofibers were investigated by X-ray diffraction analysis, Raman spectroscopy, and electron microscopies. The initial stages of the carbon erosion process were precisely examined by transmission electron microscopy coupled with elemental mapping. The segmented structure of CNF was found to be prevailing in a range of 500–650 °C. The textural parameters of carbon product (SBET and Vpore) were shown to reach maximum values (374 m2/g and 0.71 cm3/g, respectively) at the reaction temperature of 550 °C

Porous Co-Pt Nanoalloys for Production of Carbon Nanofibers and Composites

The controllable synthesis of carbon nanofibers (CNF) and composites based on CNF (Metals/CNF) is of particular interest. In the present work, the samples of CNF were produced via ethylene decomposition over Co-Pt (0–100 at.% Pt) microdispersed alloys prepared by a reductive thermolysis of multicomponent precursors. XRD analysis showed that the crystal structure of alloys in the composition range of 5–35 at.% Pt corresponds to a fcc lattice based on cobalt (Fm-3m), while the CoPt (50 at.% Pt) and CoPt3 (75 at.% Pt) samples are intermetallics with the structure P4/mmm and Pm-3m, respectively. The microstructure of the alloys is represented by agglomerates of polycrystalline particles (50–150 nm) interconnected by the filaments. The impact of Pt content in the Co1−xPtx samples on their activity in CNF production was revealed. The interaction of alloys with ethylene is accompanied by the generation of active particles on which the growth of nanofibers occurs. Plane Co showed low productivity (~5.5 g/gcat), while Pt itself exhibited no activity at all. The addition of 15–25 at.% Pt to cobalt catalyst leads to an increase in activity by 3–5 times. The maximum yield of CNF reached 40 g/gcat for Co0.75Pt0.25 sample. The local composition of the active alloyed particles and the structural features of CNF were explored

Synthesis of Chlorine- and Nitrogen-Containing Carbon Nanofibers for Water Purification from Chloroaromatic Compounds

Chlorine- and nitrogen-containing carbon nanofibers (CNFs) were obtained by combined catalytic pyrolysis of trichloroethylene (C2HCl3) and acetonitrile (CH3CN). Their efficiency in the adsorption of 1,2-dichlorobenzene (1,2-DCB) from water has been studied. The synthesis of CNFs was carried out over self-dispersing nickel catalyst at 600 °C. The produced CNFs possess a well-defined segmented structure, high specific surface area (~300 m2/g) and high porosity (0.5–0.7 cm3/g). The addition of CH3CN into the reaction mixture allows the introduction of nitrogen into the CNF structure and increases the volume of mesopores. As a result, the capacity of CNF towards adsorption of 1,2-DCB from its aqueous solution increased from 0.41 to 0.57 cm3/g. Regardless of the presence of N, the CNF samples exhibited a degree of 1,2-DCB adsorption from water–organic emulsion exceeding 90%. The adsorption process was shown to be well described by the Dubinin–Astakhov equation. The regeneration of the used CNF adsorbent through liquid-phase hydrodechlorination was also investigated. For this purpose, Pd nanoparticles (1.5 wt%) were deposited on the CNF surface to form the adsorbent with catalytic function. The presence of palladium was found to have a slight effect on the adsorption capacity of CNF. Further regeneration of the adsorbent-catalyst via hydrodechlorination of adsorbed 1,2-DCB was completed within 1 h with 100% conversion. The repeated use of regenerated adsorbent-catalysts for purification of solutions after the first cycle of adsorption ensures almost complete removal of 1,2-DCB