Flame-synthesis limits and self-catalytic behavior of carbon nanotubes using a double-faced wall stagnation flow burner

Flame-synthesis limits of carbon nanotubes (CNTs) are measured using a double-faced wall stagnation flow (DWSF) burner that shows potential in mass production of CNTs. With nitrogen-diluted premixed ethylene–air flames established on the nickel-coated stainless steel double-faced plate wall, the limits of CNT formation are determined using field-emission scanning and transmission electron microscopies and Raman spectroscopy. Also, self-catalytic behavior of the synthesized CNTs is evaluated using the DWSF burner with a CNT-deposited stainless steel double-faced plate wall. Results show narrow fuel–equivalence ratio limits of multi-walled CNT (MWCNT)-synthesis at high flame stretch rates and substantially extended limits at low flame stretch rates. This implies that the synthesis limits are very sensitive to the fuel–equivalence ratio variation for the high stretch rate conditions, yielding a lot of impurities and soot rather than MWCNTs. The enhanced ratio of tube inner diameter to wall thickness of the MWCNTs synthesized using a CNT self-catalytic flame-synthesis process is observed, indicating that the quality of metal-catalytic, flame-synthesized MWCNTs can be much improved via the process. Thus, using a DWSF burner with the CNT self-catalytic process has potential in mass production of MWCNTs with improved quality.