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Article history: The current article reviews on Chemical Vapor Deposition (CVD) methodology to synthesize Carbon
Received 5 January 2021 Nanotubes (CNTs). CVD is considered the most popular CNT synthesis methodology, which facilitates
Received in revised form 17 February 2021 the utilization of carbonaceous precursor sources, catalysts supplemented with optimized processing
Accepted 18 February 2021
conditions. It is considered as comparatively simpler and much more economical synthesis methodology
Available online 13 March 2021
with higher control, purity, and reproducibility of CNT dimensions. The growth mechanisms and process
flow are discussed. By adding green nanomaterials, we can make this process more efficient and environ-
Keywords:
ment friendly which can be used as a sustainable solution.
Carbon nanotubes
Chemical vapor deposition
Ó 2021 Elsevier Ltd. All rights reserved.
Precursor Selection and peer-review under responsibility of the scientific committee of the International Confer-
Catalyst ence on Technological Advancements in Materials Science and Manufacturing.
Support
https://doi.org/10.1016/j.matpr.2021.02.646
2214-7853/Ó 2021 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the International Conference on Technological Advancements in Materials Science and
Manufacturing.
M. Pant, R. Singh, P. Negi et al. Materials Today: Proceedings 46 (2021) 11250–11253
2. Chemical vapor deposition (CVD) of energy distribution, the breakdown of hydrocarbon molecules is
an exothermic process which discharges energy in the form of heat
CVD is considered the most prominent approach for the produc- to the surface of the metal. On the other hand, carbon crystalliza-
tion of CNTs currently. In this synthesis protocol, the reactants in tion is an endothermic process and absorbs heat from the metal
the vapor phase react close to or on the hot substrate surface. surface. Thus, this simultaneous temperature dissimilarity within
The substrate activation is achieved using thermal heating, radia- the reactor on the metal surface sustains the operation as continu-
tion, or plasma, with the final product obtained as a solid deposit ous and sustainable.
with the deposition usually occurring at a thermal gradient ranges Based on the contact angle between the metal and substrate,
in the order of 1000℃. In other words, the product deposits consist two discreet models were developed for the CNT synthesis. The
of either homogenous gas-phase reactions or heterogeneous chem- two widely accepted models to describe the production of CNTs
ical reactions ensuing in the materialization of solid deposits (pow- are represented in Fig. 1(a) and (b). In the tip-growth model [5],
ders or coatings). The final product properties are differentiated by the metal forms an acute contact angle with the substrate and thus
varying several process parameters such as substrate temperature, catalyst-substrate interaction is weak. The hydrocarbon molecule
the composition of the reaction gas mixture, total pressure gas disintegrates on the surface of the metal and the carbon diffuses
flow, and experimental conditions, etc. The volatile reactant feed down through the metal. CNT precipitates through the metallic
in the gaseous phase, which comprises of carbon source (deposit core and pushes all metallic particles off the substrate surface. As
material) is subsequently transported to the hot substrate surface long as the top of the metal is available for the decomposition of
using a carrier gas (hydrogen or nitrogen). In cases, when the fresh hydrocarbons (there is a concentration gradient in the metal
two feed constituents (i.e., reactant and deposit) are of a similar which allows the carbon to diffuse), the CNT grows continuously.
constitution, the gasification operation is supplemented utilizing As soon as the metal is completely covered with an excess of car-
the carrier gas with the reactant. Carrier gas transport is dependent bon, its catalytic activity stops and the overall growth of CNTs is
on the equilibrium constant of the temperature difference between finally at the halt. In base-growth model [6], the metal forms an
the two sources (substrate and reactant) [3,4]. Thus, it is essential, obtuse contact angle with the substrate and thus the catalyst–sub-
that individual units of the synthesis protocol must be in temper- strate interaction is strong. The decomposition of hydrocarbons
ature equilibrium with the transport gas otherwise vapor conden- and the diffusion of carbon are quite similar to the tip-growth
sation will arise on the contact with any cool surface. Hence, the model, but the CNT precipitation does not push the metal particles
reactive chemical constituents and surfaces of the system involved upwards. Thus, the precipitate proceeds to exit by the tip of the
in the reaction are comparatively at a higher temperature than the metal (further from the substrate, with minimal interaction). The
transport gas supply. However, the overall temperature should be carbon first crystallizes as a hemispherical dome (the cheapest
relatively lower as compared to the melting point of deposit mate- closed carbon lattice in a spherical nanoparticle), which then prop-
rial, along-with two important considerations viz. ‘‘gaseous phase agates upward as a seamless graphite cylinder. Subsequent deposi-
is essential for successful elimination of unwanted materials” tion of hydrocarbons occurs at the lower circumferential metal’s
and, ‘‘deposits must have low vapor to prevent volatilization phe- surface and diffuses upward as dissolved carbon. Therefore, CNT
nomenon”. The aforementioned deposition reaction ensues with synthesis propagates atop the catalyst particle sited at the base.
thermal decomposition or with chemical reduction. The production of SWCNT or MWCNT is governed by the particle
size of the catalyst in the chemical process [7]. Hence, when parti-
2.1. Principle cle size is in few nm, SWCNT formation occurs and when in tens of
nm favors MWCNT production.
The most recognized CNT growth mechanism is discussed in
this subsection. The carrier gas transports hydrocarbon vapour in 2.2. Methodology
contact with metal nanoparticles present in the systemic reactor
at higher temperatures. During the reaction, the hydrocarbon Fig. 1 represents a basic schematic diagram of the experimental
molecule disintegrates into individual carbon and hydrogen spe- set-up used in CVD methodology for CNT growth. The chemical
cies which further translates to the accumulation of carbon onto synthesis production approach comprises of a tubular reactor for
the surface of the material as hydrogen escapes away. Carbon sol- hydrocarbon vapor treatment (15–60 min) in which the catalyst
ubility onto the metal surface, if any, is considered to be saturated material (at 600–1200℃) is responsible for hydrocarbon break-
and after this crystallization of carbon framework is widely down. The novel synthesized CNTs propagate on the surface of cat-
accepted. As soon as, dissolved carbon precipitates out, the remain- alyst within the high-temperature reactor environment and are
ing carbon crystallizes in the form of the cylindrical framework finally procured after the cooling of the system. In cases where liq-
with no hanging bonds and result in energetically stable. In terms uid state hydrocarbon compounds (benzene, alcohol, etc.) are used
11251
M. Pant, R. Singh, P. Negi et al. Materials Today: Proceedings 46 (2021) 11250–11253
as a precursor, it is heated in a flask and thus an inert (non- matter with ring carbon content to be used as a carbon precursor.
reactive) gas is passed through, which transports the hydrocarbon Although, with changes in carbon source the overall processing
vapor inside the systemic reactor for CNT production. But in cases conditions have to be optimized for maximum overall yield. Thus,
of solid hydrocarbon as the CNT precursor, the solid precursor can reproducibility of the high quality and quantity of the CNT pro-
be placed directly inside the low-temperature zone of the reaction duced is a major benchmark for future investigations. Similarly,
chamber. Solid volatile materials, displaying the sublimation phe- impurities in the organic precursor would lower the overall yield
nomenon with phase change from solid to vapor can be trans- and thus prior utilization requires pre-processing of the organic
ported to the high-temperature zone bypassing the volatile source. The pre-treatment may be either physical or chemical
precursor compound over the catalyst surface. treatment to maintain consistent constituent chemistry of the
Similarly, the catalyst precursors can also be used in any phase: organic sources which may use as a sustainable industrial
solid, liquid or gas, and are appropriately used in the systemic reac- approach. The catalysts are required in the production of CNT to
tor or can be simultaneously fed from outside. In a process known lower the temperature of hydrocarbon decomposition as compared
as the floating catalyst method, catalyst vapor pyrolysis is con- to spontaneous decomposition temperatures. The nanometer-sized
ducted at a suitable temperature which in turn releases in-situ metal particles of Iron, Cobalt, and Nickel are commonly used due
metal nanoparticles. Moreover, catalyst coated substrates can be to comparatively high carbon solubility and higher carbon diffu-
used in the reaction and placed inside the systemic reactor to ini- sion rate at higher temperatures. Additionally, higher melting
tiate CNT growth. Several contradictory theories have emerged on point and low equilibrium vapor pressure provide a significant
the reaction conditions and post-deposition product analyses effect in the selection of a wide temperature range for CVD synthe-
which shows lack of significant process protocol for standardiza- sis. This methodology is a temperature-dependent process and in
tion of the systemic reaction process. Therefore, there is no defini- each stage, a characteristic threshold temperature value is essen-
tive CNT growth mechanism to date. tial for optimized synthesis [18]. In most of the reported findings,
at least 500℃ or higher is required for CNT production. It is gener-
ally in consensus that higher temperatures ranges (1000–2000 ℃)
2.3. Process parameters
favor the production of SWCNTs over MWCNTs [19]. Thus, repre-
senting temperature as a significant variable for CNT diameter con-
The process methodology of CNT synthesis is dependent on sev-
eral parameters such as precursor hydrocarbons, catalysts, thresh- trol and these findings were concomitant with other reports as
well [20–22]. Thus, the higher growth temperature is favored for
old temperature, processing time, pressure, and gas flow rate.
Some of these parameters are discussed in brief as follows. The well-defined and crystallized nanotube, in conjunction with
parameters such as yield and purity, but on the subjection of
structural orientations of the hydrocarbon molecule (precursor)
have a profound effect on the CNT properties. For example, linear higher temperatures, detrimental observations were also reported
[18,23]. Hence, size, shape and stability are essential for catalytic
hydrocarbon molecules (i.e., methane, acetylene, etc.) can disinte-
grate into carbon atoms or in various arrangements (dimers/tri- nanoparticles at lower temperatures, which proceeds to better
control the size and chirality of CNTs. The processing time opti-
mers) and generally result in the production of straight hollow
CNTs. However, cyclic hydrocarbons molecules (i.e., benzene, mization is also essential in terms of product quality and process
yield, and if altered can be detrimental in nucleation and can fur-
cyclohexane, etc.) are responsible for the production of relatively
curved CNTs, with tube walls often joined inside [8,9]. The com- ther cause progressive deactivation of the catalytic nanoparticles
which reduces overall yield. However, variability is observed in
monly investigated precursor molecules include methane, ethanol,
ethylene, acetylene, benzene, etc. Current investigations are based various reports in terms of the optimum time for CNT production
using CVD technique in various carbon sources [18,24–28]. To ini-
on the CNT synthesis utilizing environment-friendly carbon pre-
cursors from the biological origin and have developed conditions tiate CNT synthesis, accumulated carbon atoms on the substrate
surface must reach a critical concentration inside the catalyst par-
for growing CNT [10–12]. Moreover, aligned, and non-aligned CNTs
have been stated as a final output from cheap raw materials utiliz- ticles. It is dependent on carbon precursor nature, catalyst compo-
sition, and temperature [29]. Moreover, CNTs display various
ing plant-based substrates (i.e., turpentine [13–15], eucalyptus oils
[16], green grasses [17], etc.) with significant shreds of evidence. morphologies for different reacting times, as reported for SWCNT
growth attributed to shorter reaction time [30] and CNT diameter
This presents an exciting prospect for the utilization of any organic
11252
M. Pant, R. Singh, P. Negi et al. Materials Today: Proceedings 46 (2021) 11250–11253
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