Synthesis of carbon nanotubes using mesoporous Fe-MCM-41 catalysts

MWNTs (multi-walled carbon nanotubes) were made by catalytic CVD process using iron-containing mesoporous silica, Fe-MCM-41, with 4 mol% Fe loading prepared by direct synthesis route. Uniform 5 nm size Fe2O3 nano-particles impregnated onto a mesoporous silica support, SBA-15 were also prepared for CNTs synthesis. The catalysts were characterized using XRD, SEM/TEM, N2 physisorption, UV-vis diffuse reflectance and FT-IR spectroscopies. Acetylene gas was introduced as a carbon source, and the gas mixture of Ar:H2:C2H2 = 14:5:1 pyrolyzed at 750 degrees C for 60 min was found to be the optimum synthesis condition. Fe-MCM-41 due to higher dispersion of nano-sized Fe-species was efficient as catalyst for MWNTs with more uniform size distribution. Cobalt-impregnated Fe-MCM-41 (Co/Fe = 1) produced a small fraction of SWNTs of ca. 2 nm diameter mixed with MWNTs.