CA2293547C - Method and device for producing fullerenes - Google Patents
Method and device for producing fullerenes Download PDFInfo
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- CA2293547C CA2293547C CA002293547A CA2293547A CA2293547C CA 2293547 C CA2293547 C CA 2293547C CA 002293547 A CA002293547 A CA 002293547A CA 2293547 A CA2293547 A CA 2293547A CA 2293547 C CA2293547 C CA 2293547C
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- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
- C01B32/00—Carbon; Compounds thereof
- C01B32/05—Preparation or purification of carbon not covered by groups C01B32/15, C01B32/20, C01B32/25, C01B32/30
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
- B01J19/08—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor
- B01J19/087—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor employing electric or magnetic energy
- B01J19/088—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor employing electric or magnetic energy giving rise to electric discharges
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- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
- C01B32/00—Carbon; Compounds thereof
- C01B32/15—Nano-sized carbon materials
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- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
- C01B32/00—Carbon; Compounds thereof
- C01B32/15—Nano-sized carbon materials
- C01B32/152—Fullerenes
- C01B32/154—Preparation
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05H—PLASMA TECHNIQUE; PRODUCTION OF ACCELERATED ELECTRICALLY-CHARGED PARTICLES OR OF NEUTRONS; PRODUCTION OR ACCELERATION OF NEUTRAL MOLECULAR OR ATOMIC BEAMS
- H05H1/00—Generating plasma; Handling plasma
- H05H1/24—Generating plasma
- H05H1/26—Plasma torches
- H05H1/32—Plasma torches using an arc
- H05H1/42—Plasma torches using an arc with provisions for introducing materials into the plasma, e.g. powder, liquid
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
- B01J2219/08—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor
- B01J2219/0894—Processes carried out in the presence of a plasma
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S977/00—Nanotechnology
- Y10S977/70—Nanostructure
- Y10S977/734—Fullerenes, i.e. graphene-based structures, such as nanohorns, nanococoons, nanoscrolls or fullerene-like structures, e.g. WS2 or MoS2 chalcogenide nanotubes, planar C3N4, etc.
- Y10S977/742—Carbon nanotubes, CNTs
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S977/00—Nanotechnology
- Y10S977/70—Nanostructure
- Y10S977/832—Nanostructure having specified property, e.g. lattice-constant, thermal expansion coefficient
- Y10S977/835—Chemical or nuclear reactivity/stability of composition or compound forming nanomaterial
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S977/00—Nanotechnology
- Y10S977/84—Manufacture, treatment, or detection of nanostructure
- Y10S977/842—Manufacture, treatment, or detection of nanostructure for carbon nanotubes or fullerenes
- Y10S977/844—Growth by vaporization or dissociation of carbon source using a high-energy heat source, e.g. electric arc, laser, plasma, e-beam
Abstract
The invention relates to a method and a device for the continuous production of carbon black with a high fullerene content. The device essentially consis ts of a plasma reactor (1), a downstream heat separator (2) to separate the non - liquid constituents and a cold separator (3) attached thereto.
Description
Yvan Schwob November 30, 1999 E31681 G/Wg/rnh Mcthod and Device for Producine Fullerenes The invention relates to a method and a device for the continuous production of carbon black with a high fullerene content.
lo In the following the term fullerenes refers to molecular, chemically homogenous and stable fullerenes. Representatives of this group of fullerenes are C60, C70 or Cga. Thesc fullcrcncs are gcncrally soluble in aromatic solvents. A
partieularly preferred fullerene is the C60 fullerene.
For the production of carbon black containing fullerenes several methods are known. However, thc achicvable conccntration of fullerenes in the obtained carbon black is so low that a preparation of pure fullerenes is only possible with great expenditures. Due to the resulting high price of pure fu]lerenes interesting applications in different fields of technology are for economical reasons a priori not conceivable. The US-A 5,227,038 for example, discloscs an apparatus for a laboratory allowing to produce a few grams of fullerenes in a discontinuous way by means of an electric arc between carbon electrodcs scrving as a raw matcrial.
Apart from the fact that the produced amounts are tiny, the concentration of fullerenes C60 in the deposited carbon black is very low and ncvcr exceeds 10 %
of the produccd mass. Further, the fullerene C60 is in this method present in a mixture with higher fullerene compounds requiring costly fractionation for an isolation with sufficient purity.
lo In the following the term fullerenes refers to molecular, chemically homogenous and stable fullerenes. Representatives of this group of fullerenes are C60, C70 or Cga. Thesc fullcrcncs are gcncrally soluble in aromatic solvents. A
partieularly preferred fullerene is the C60 fullerene.
For the production of carbon black containing fullerenes several methods are known. However, thc achicvable conccntration of fullerenes in the obtained carbon black is so low that a preparation of pure fullerenes is only possible with great expenditures. Due to the resulting high price of pure fu]lerenes interesting applications in different fields of technology are for economical reasons a priori not conceivable. The US-A 5,227,038 for example, discloscs an apparatus for a laboratory allowing to produce a few grams of fullerenes in a discontinuous way by means of an electric arc between carbon electrodcs scrving as a raw matcrial.
Apart from the fact that the produced amounts are tiny, the concentration of fullerenes C60 in the deposited carbon black is very low and ncvcr exceeds 10 %
of the produccd mass. Further, the fullerene C60 is in this method present in a mixture with higher fullerene compounds requiring costly fractionation for an isolation with sufficient purity.
The US-A 5,304,366 describes a method allowing a certain concentration of the product but using a system for filtering a gas circulation at a high temperature which is difficult to practically perform.
The EP-B 1 0 682 561 describes a general method for the production of carbon black with a nanostructure defined by the influence of a gaseous plasma on carbon at high temperatures. In product series obtained in this way fullerenes may at sufficient treatment temperatures be obtained in a continuous technical way.
However, the reaction products resulting from the method according to EP-B 1 0 561 are very impure and contain apart from carbon which has not been transformed into fullerenes at best 10 % fullerene C60 as a mixture with higher fullerenes.
It was therefore the problem of the invention to develop a device and a method allowing to continuously produce carbon black with a high content of fullerenes. This problem was solved with the device according to thc invention according to claim 1 and the method according to claim 12 based thereon.
According to one aspect of the invention, there is provided a device for the continuous production of carbon black with a high content of fullerenes from carbon-containing compounds in a plasma consisting of a) a plasma reactor consisting of a first reaction chamber in which two or more electrodes are inserted, wherein the first reaction chamber further includes a supply arrangement for the plasma gas and the carbon-containing compounds to lead the plasma gas and the carbon-containing compounds centrally into a reaction zone, wherein the plasma reactor includes a second reaction chamber adjacent to the first reaction chamber having suitable means for cooling the reaction mixture exiting from the first reaction chamber, b) a heat separator attached to the plasma reactor; and c) a cold separator attached to the heat separator.
2a Description of the Figures:
Figure 1: shows an embodiment of the device according to the invention, consisting essentially of a plasma reactor (1) with a first reaction chamber (A) and a second reaction chamber (B), a downstream heat separator and an attached cold separator (3).
Figure 2: shows a detail of the head part of the plasma reactor (1) comprising essentially the first reaction chamber (A).
Figure 3: shows a top view of the reactor (1) illustrating an embodiment of the invention with three electrodes (4) distributed with an angle of 120 , a central supply device (5) for the carbon-eontaining material and a heat resistant and heat isolating lining.
Figure 4: shows a furcher embodiiment of the devicc according to thc invention consisting cssentially of the same parts as figure 1, but wherein the flow of products in the plasma reactor (1) is dircctcd oppositc to gravity.
The device according to the invention consists according to claim 1 of the following components:
a) a plasma reactor (1) consisting of a first rcaction chamber (A) into which two or more electrodes (4) are inserted; the first reaction chamber (A) further comprising a supply arrangernent (5) for the plasma gas and the carbon-containing compounds delivering the plasma gas and the carbon-containing compounds centrally into the rcaction zonc; the plasma reactor (1) comprising a second reaction chainber (B) adjacent to the first reaction chamber (A) comprising suitable arrangements for cooling the reaction mixture exiting from the first reaction chamber (A), b) a heat scparator (2) attached to the plasma reactor, and c) a cold separator (3) attached to the heat separator (2).
The plasma reactor (1) consists preferably of a cylindrically-shaped metal casing which may, if needed. be designed with a double wall. In this double wall a suitable cooling means may circulate. In the metal casing further an isolation (6) may be provided consisting gcncrally of graphite' or additionally of a ceramic =4-laycr. The first rcaction chamber (A) is only used for the plasma reaction at very high temperatures.
According to the invention two or more, preferably three electrodes (4) arc inserted into the hcad part of the first reaction chamber (A). The electrodes are preferably arranged with an angle to the axis so that they form in the upper part of the first reaction chambcr (A) an intcrscction and that they can individually and continuously be adjusted by conduit glands (7). The rilt with respect to the vertical axis is preferably in the range of 15 to 90 , howcvcr, in all cases the tilt is such i o that an easy start of the arc producing the plasma is possible and that a maximal stability of the plasma is assured.
Preferably, the electrodes (4) are equally distributed so that with thrcc clectrodes an angular distance of 1201 results. Typically plasma electrodes are used which are common in the field of the experts. These electradcs consist typically of a graphite as purc as possible in the form of a cylindrical rod having generally a diameter of a few centimeters. If needed, the graphite may contain further clcmcnts having a stabilizing influence on the plasma.
2o The electrodes are generally operated with an aiternating voltage between 50 and 500 volts. The applied power is typically in the range of 40 kW to 150 kW. A
suitable control of the electrodcs provides a constant and stable plasma zone.
The electrodes are automatically readjusted corresponding to their consumption.
The supply device (5) serves as a feeding unit for the carbon-contaiuming compounds as well as for the plasma gas. Dcviccs allowing a constant supply common for an expert can be used to this end. The supply is preferably centrally into the plasma zone controlled by the elecrrodes. The second reaction chamber (B) comprises suitable devices for an effective and selective cooling of the reaction mixture exiting from the first reaction chambcr (A). In a preferred embodiment a supply device (8) may be provided thereto allowing for exaznplc by a cyclone effect a suitable distribution of, for example a plasma gas or, if needed, another cooling means.
According to the invention, the reaction mixture exiting from the second reaction chamber (B) is delivered to a heat separator (2). The heat separator (2) is preferably designed in the form of an isolated or isothermally heated cyclone containing in the lower part a lock (9) for the separation of the non-volatile components, a conduit (10) for the recovery of the non-volatile components into the plasma reactor (10) and in the upper part a conduit (11) for leading the volatile components into the cold separator (3). The isothermal heating of the cyclone can be achieved by common measures.
Alternatively, the heat separator may be replaced by a suitable heat-resistant filter.
Such a filter can, for example, consist of heat-resisting materials and of a porous ceramic, a metal fix or graphite foam. As in the case of the heat separator devices which are not shown, may allow a recovery of the separated solid compounds and lines may be provided for leading the gaseous compounds into the cold separator (3).
A cold separator (3) is connected to the heat separator (2) and is preferably in the form of a cyclone which can be cooled and which comprises in the lower part a lock (12) for the separation of the carbon black containing the fullerenes and in the upper part a conduit (10) for guiding the plasma gas back into the plasma reactor (1).
The cooling of this cyclone may be carried out in a standard way, for example by means of a cooling jacket supplied with a cooling fluid.
In a further embodiment of the device according to the invention a conduit (13) for the supplying of the cooling device of the second reaction chamber (B) may be branched off from the conduit (10).
Further, also an entry device (14) for the carbon-containing material may be present allowing to feed the carbon-containing material via a lock (15) into the conduit (10).
S
A further subject of the invention is a method for the production of carbon black with a high contcnt of the fullerenes mentioned at the beginning from carbon-containing compounds in a plasma by means of the abovc-dcscribcd device according to the invention. The invention relates in particular to the production of carbon black with a high content of C60 fullerenes.
Preferably, the temperature of the plasma is adjusted so that the greatest volatility possible of the insertcd carbon-containing material is achieved. Generally the minimum of the temperature in the first reaction chamber (A) is 4000 C.
As the plasma gas preferably a noble gas or a mixture of different noble gases is used. Preferably helium, if needed in a mixture with a diffcrcnt noblc gas, is used.
The used noble gases should be as pure as possible.
As the carbon-containing material preferably a highly pure carbon is used which is as free as possible of interfering and the quality of the fullerencs ncgatively influencing impurities. Impurities as for example, hydrogen, oxygen or sulfur reduce the production yield of fullerenes and form undesircd byproducts. On the other hand any gascous impurity present in the circulation of the production cycle causes a decrease of the puriry of the plasma gas and requires the supply of plasma gas in a purc form to maintain the original composition. However, it is also possible to directly clean the plasma gas in the circulation of the production cycle. Preferably, highly pure, finely ground carbon powders e.g, acetylene black, graphite powders, carbon black, ground pyrolytic graphite or highly calcinatcd coke or mixtures of the mcntioned carbons are used: In order to obtain an optimal evaporation in the plasma, the mentioned carbon powders are prcfcrably as fine as possible. Coarser carbon particles may pass the plasma zone without being vaporized. In this case a device according to figure 4 may help wherein the carbon particles reach the plasma zone in the opposite direction with respect to gravity, The carbon-containing material is preferably together with the plasma gas supplied via the supply arrangement (5) into the plasma rcactor.
The plasma gas contains the carbon-containing material preferably in an aznount of 0.1 kg/m3 to 5 kg/m~.
The reaction mixture formed in the reaction chamber (A) is, as already rnentioned above, with a sufficient efficiency cooled in the second reaction chamber (B) to keep it at a temperaturc of prefera.bly bclwccn 1000 C and 2700 C for a defined time of generally fractions of a second up to a second. In this phase the gaseous carbon molecules exiting from the first reaction chamber (A) recombine to the fullerenes mentioned at the beginning.
The cooling is achicvcd, as shown above, by suitable cooling devices, preferably by a homogenous distribution of a defined amount of cold plasma gas in the second reaction chamber (B). This cold plasma gas is preferably obtained from the recirculating plasma gas.
At thc ea:it of the second reaction chamber (B) the mixture consists generally of the plasma gas, the desired fitllerenes in a gaseous statc. a fraction of the non-convertcd raw material and of non-vaporizable fullerenes.
In the heat separator (2), which is, as shown above, provided as a cyclone, the solid parts are separated from the gaseous parts by =nn.eans of the cyclone cffcct.
The desired fullerene, which is volatile itseli; can therefore with a yield of up to 90 % be separated from the other non-volatile carbon compounds.
The heat separator (2) is kept by known mezms isothermally on a tentperature of prcfcrably between 600 C to 1000 C to avoid any condensation of the desired ffiillerenes in any of their parts.
A lock (9) at the bottom of the heat separator (2) allows to lead the carbon which was not converced into the desired fullerene back into the gas circulation, for 1 o example by means of a blowing engine.
The abovc-mcntioncd but not in detail explained filter may fulfil tha same function as the above-discussed heat separatot (2).
A cold separator (3) follows the heat separator (2). This cold separator is by means of any known means cooled to a teuaperatme sufficient for the condensation of the desired fullerene, preferable of a temperature ranging from room temperature up to 200 C_ 2o At the exit of the cold separator (3) generally a powder-like material accumulates oon7Ai*++r-g carbon black with s fisction of the desired fullvre=es of up to d0 %.
Thanks to the lock (12) the carbon black with the accumulated desired fullereacs may be taken from the process and be subjected to further purification. The fiuther purification may be carried out in accordance with a known method, for example by extraction (Dresselbaus et al., Science of Fullerenes and Carbon Nanotubes, Acadcmic Press, 1996, Chapter 5, pp. 111, in particular Chapters 5.2 and 5.3).
The plasma gas coming from the cold separator (3) can be lead back, for example by means of a blowing machine, via the conduit (10) into the plasma reactor (1).
A branch (13) of this conduit (10) allows to guide a part of the cold flow back into the second reaction chamber (B) for cooling the reaction mixture.
The following examples illustrate the subject matter of the invention, howcver, w-ithout limiting it to the scope of the examples.
Examples:
Example 1 The device consists of a cylindrical rcactor with an inner diameter of 300 mm, a height of 150 cm and a double-walled cooling jacket with water circulation.
$etween the graphite lining and the inncc wall of the pressure chamber an isolsting layer of graphite foam is arranged. Three graphite electrodes with a cliaoaetez of 20 mm are positioned with a sliding device through the reactor cover by means of conduit glands inserted into electrically isolating sockets. A
central conduit with a diameter of 3 mm scrvcs for introducing the graphite suspension into the plasmagenic gas. The plasma gas is rure helium kept in a circulation.
The electrodes are supplied with an alternating voltage such that the supplied power is 100 kW.
By a means of a three-phase controller of the type used in an arc furnace comparatively constant electrical properties on the plasma level are achieved.
In this way a plasma temperature of approximately 5000 C is kept in the reaction chamber (A)_ S
The reaction chamber (B) is provided with cold gas guided back to keep its temperature on a value of approximately 1600 T.
The raw material is micronized graphite of the type TZMREXO KS 6 of Timcal Atl. CH-Sins. With an unount of gas of 10 ra3/h on the height of the entrance of the reactor and a material addition of 10 kg/h, a permanent state is achieved after an operating time of 1 hour. In the heat separator (2), kept on a temperature of 800 C, 8 kg/h of non-volatile carbon compounds were separated via the lock (9) and recovered. It was found that approximatcly 6% of the introduced carbon was under these conditions converted into the gaseous fullerene C68. With an effieieney of the heat scparator of approximatcly 90 % the fuliercne C60 was to a small extent mixed with non-volatile carbon compounds and helium. This aerosol was transmitted to the cold scparator (3) kept on a tcmpcrature of 150 C.
2o The product accumulating at the bottom oP the cold separator (3) was during constant opcration removcd from the lock (12) in an amount of 2 kg/h and consisted of 30 % fullerene C60 as a mixture with non-convezted carbon.
The obtained product can in this state be used, however it was further purified according to Dresselbaus et al., Seience of Fullcrcncs and Carbon Nanotubes, Acadcmic Press, 1996, Chapter 5, pp. 111, in particular Chapters 5.2 and 5.3, by extraction with toluol. The exemplary production allows the production of 0.6 kg/h of pure fullerene C6o.
Example 2 The method according to example 1 was repeated, only helium was replaced by argon. Undcr thcsc conditions pure fullerenc C60 could bc obtaincd aftcr purification in the amount of 0.4 kgih.
Example 3 The method according to example 1 was repeated, only the heat separator (2) was rcplaccd by a filter of porous ccramic. The gas flow coming fr+om the filter and entering the cold separator (3) consisted only of helium mixed with gaseous fullerene C60. Thc cfficicncy of the filtcr was approximately 90 %. According to this method pure fullerene C60 could be obtained after purification with an amount of 0.6 kg/h.
Example 4 A method according to example 1 was repeated, only the micronizcd graphite was replaced by a highly pure acetylene black of the company SN2A, F-Berre 1'Etang.
With this mcthod purc fullcrcne C6o with an amount of 0.8 kg/h could bc obtaincd after purification.
Example 5 The method according to example 1 was repeated, only the micronized graphite was rcplaccd by a highly pure, dcgasscd pyrolytic graphitc of the type ENSACO
Super P of the company MMM-Carbon, B-Brussels. With this method pure fullerenc C60 with an amount of 0.7 kg/h could be obtained after purification.
The EP-B 1 0 682 561 describes a general method for the production of carbon black with a nanostructure defined by the influence of a gaseous plasma on carbon at high temperatures. In product series obtained in this way fullerenes may at sufficient treatment temperatures be obtained in a continuous technical way.
However, the reaction products resulting from the method according to EP-B 1 0 561 are very impure and contain apart from carbon which has not been transformed into fullerenes at best 10 % fullerene C60 as a mixture with higher fullerenes.
It was therefore the problem of the invention to develop a device and a method allowing to continuously produce carbon black with a high content of fullerenes. This problem was solved with the device according to thc invention according to claim 1 and the method according to claim 12 based thereon.
According to one aspect of the invention, there is provided a device for the continuous production of carbon black with a high content of fullerenes from carbon-containing compounds in a plasma consisting of a) a plasma reactor consisting of a first reaction chamber in which two or more electrodes are inserted, wherein the first reaction chamber further includes a supply arrangement for the plasma gas and the carbon-containing compounds to lead the plasma gas and the carbon-containing compounds centrally into a reaction zone, wherein the plasma reactor includes a second reaction chamber adjacent to the first reaction chamber having suitable means for cooling the reaction mixture exiting from the first reaction chamber, b) a heat separator attached to the plasma reactor; and c) a cold separator attached to the heat separator.
2a Description of the Figures:
Figure 1: shows an embodiment of the device according to the invention, consisting essentially of a plasma reactor (1) with a first reaction chamber (A) and a second reaction chamber (B), a downstream heat separator and an attached cold separator (3).
Figure 2: shows a detail of the head part of the plasma reactor (1) comprising essentially the first reaction chamber (A).
Figure 3: shows a top view of the reactor (1) illustrating an embodiment of the invention with three electrodes (4) distributed with an angle of 120 , a central supply device (5) for the carbon-eontaining material and a heat resistant and heat isolating lining.
Figure 4: shows a furcher embodiiment of the devicc according to thc invention consisting cssentially of the same parts as figure 1, but wherein the flow of products in the plasma reactor (1) is dircctcd oppositc to gravity.
The device according to the invention consists according to claim 1 of the following components:
a) a plasma reactor (1) consisting of a first rcaction chamber (A) into which two or more electrodes (4) are inserted; the first reaction chamber (A) further comprising a supply arrangernent (5) for the plasma gas and the carbon-containing compounds delivering the plasma gas and the carbon-containing compounds centrally into the rcaction zonc; the plasma reactor (1) comprising a second reaction chainber (B) adjacent to the first reaction chamber (A) comprising suitable arrangements for cooling the reaction mixture exiting from the first reaction chamber (A), b) a heat scparator (2) attached to the plasma reactor, and c) a cold separator (3) attached to the heat separator (2).
The plasma reactor (1) consists preferably of a cylindrically-shaped metal casing which may, if needed. be designed with a double wall. In this double wall a suitable cooling means may circulate. In the metal casing further an isolation (6) may be provided consisting gcncrally of graphite' or additionally of a ceramic =4-laycr. The first rcaction chamber (A) is only used for the plasma reaction at very high temperatures.
According to the invention two or more, preferably three electrodes (4) arc inserted into the hcad part of the first reaction chamber (A). The electrodes are preferably arranged with an angle to the axis so that they form in the upper part of the first reaction chambcr (A) an intcrscction and that they can individually and continuously be adjusted by conduit glands (7). The rilt with respect to the vertical axis is preferably in the range of 15 to 90 , howcvcr, in all cases the tilt is such i o that an easy start of the arc producing the plasma is possible and that a maximal stability of the plasma is assured.
Preferably, the electrodes (4) are equally distributed so that with thrcc clectrodes an angular distance of 1201 results. Typically plasma electrodes are used which are common in the field of the experts. These electradcs consist typically of a graphite as purc as possible in the form of a cylindrical rod having generally a diameter of a few centimeters. If needed, the graphite may contain further clcmcnts having a stabilizing influence on the plasma.
2o The electrodes are generally operated with an aiternating voltage between 50 and 500 volts. The applied power is typically in the range of 40 kW to 150 kW. A
suitable control of the electrodcs provides a constant and stable plasma zone.
The electrodes are automatically readjusted corresponding to their consumption.
The supply device (5) serves as a feeding unit for the carbon-contaiuming compounds as well as for the plasma gas. Dcviccs allowing a constant supply common for an expert can be used to this end. The supply is preferably centrally into the plasma zone controlled by the elecrrodes. The second reaction chamber (B) comprises suitable devices for an effective and selective cooling of the reaction mixture exiting from the first reaction chambcr (A). In a preferred embodiment a supply device (8) may be provided thereto allowing for exaznplc by a cyclone effect a suitable distribution of, for example a plasma gas or, if needed, another cooling means.
According to the invention, the reaction mixture exiting from the second reaction chamber (B) is delivered to a heat separator (2). The heat separator (2) is preferably designed in the form of an isolated or isothermally heated cyclone containing in the lower part a lock (9) for the separation of the non-volatile components, a conduit (10) for the recovery of the non-volatile components into the plasma reactor (10) and in the upper part a conduit (11) for leading the volatile components into the cold separator (3). The isothermal heating of the cyclone can be achieved by common measures.
Alternatively, the heat separator may be replaced by a suitable heat-resistant filter.
Such a filter can, for example, consist of heat-resisting materials and of a porous ceramic, a metal fix or graphite foam. As in the case of the heat separator devices which are not shown, may allow a recovery of the separated solid compounds and lines may be provided for leading the gaseous compounds into the cold separator (3).
A cold separator (3) is connected to the heat separator (2) and is preferably in the form of a cyclone which can be cooled and which comprises in the lower part a lock (12) for the separation of the carbon black containing the fullerenes and in the upper part a conduit (10) for guiding the plasma gas back into the plasma reactor (1).
The cooling of this cyclone may be carried out in a standard way, for example by means of a cooling jacket supplied with a cooling fluid.
In a further embodiment of the device according to the invention a conduit (13) for the supplying of the cooling device of the second reaction chamber (B) may be branched off from the conduit (10).
Further, also an entry device (14) for the carbon-containing material may be present allowing to feed the carbon-containing material via a lock (15) into the conduit (10).
S
A further subject of the invention is a method for the production of carbon black with a high contcnt of the fullerenes mentioned at the beginning from carbon-containing compounds in a plasma by means of the abovc-dcscribcd device according to the invention. The invention relates in particular to the production of carbon black with a high content of C60 fullerenes.
Preferably, the temperature of the plasma is adjusted so that the greatest volatility possible of the insertcd carbon-containing material is achieved. Generally the minimum of the temperature in the first reaction chamber (A) is 4000 C.
As the plasma gas preferably a noble gas or a mixture of different noble gases is used. Preferably helium, if needed in a mixture with a diffcrcnt noblc gas, is used.
The used noble gases should be as pure as possible.
As the carbon-containing material preferably a highly pure carbon is used which is as free as possible of interfering and the quality of the fullerencs ncgatively influencing impurities. Impurities as for example, hydrogen, oxygen or sulfur reduce the production yield of fullerenes and form undesircd byproducts. On the other hand any gascous impurity present in the circulation of the production cycle causes a decrease of the puriry of the plasma gas and requires the supply of plasma gas in a purc form to maintain the original composition. However, it is also possible to directly clean the plasma gas in the circulation of the production cycle. Preferably, highly pure, finely ground carbon powders e.g, acetylene black, graphite powders, carbon black, ground pyrolytic graphite or highly calcinatcd coke or mixtures of the mcntioned carbons are used: In order to obtain an optimal evaporation in the plasma, the mentioned carbon powders are prcfcrably as fine as possible. Coarser carbon particles may pass the plasma zone without being vaporized. In this case a device according to figure 4 may help wherein the carbon particles reach the plasma zone in the opposite direction with respect to gravity, The carbon-containing material is preferably together with the plasma gas supplied via the supply arrangement (5) into the plasma rcactor.
The plasma gas contains the carbon-containing material preferably in an aznount of 0.1 kg/m3 to 5 kg/m~.
The reaction mixture formed in the reaction chamber (A) is, as already rnentioned above, with a sufficient efficiency cooled in the second reaction chamber (B) to keep it at a temperaturc of prefera.bly bclwccn 1000 C and 2700 C for a defined time of generally fractions of a second up to a second. In this phase the gaseous carbon molecules exiting from the first reaction chamber (A) recombine to the fullerenes mentioned at the beginning.
The cooling is achicvcd, as shown above, by suitable cooling devices, preferably by a homogenous distribution of a defined amount of cold plasma gas in the second reaction chamber (B). This cold plasma gas is preferably obtained from the recirculating plasma gas.
At thc ea:it of the second reaction chamber (B) the mixture consists generally of the plasma gas, the desired fitllerenes in a gaseous statc. a fraction of the non-convertcd raw material and of non-vaporizable fullerenes.
In the heat separator (2), which is, as shown above, provided as a cyclone, the solid parts are separated from the gaseous parts by =nn.eans of the cyclone cffcct.
The desired fullerene, which is volatile itseli; can therefore with a yield of up to 90 % be separated from the other non-volatile carbon compounds.
The heat separator (2) is kept by known mezms isothermally on a tentperature of prcfcrably between 600 C to 1000 C to avoid any condensation of the desired ffiillerenes in any of their parts.
A lock (9) at the bottom of the heat separator (2) allows to lead the carbon which was not converced into the desired fullerene back into the gas circulation, for 1 o example by means of a blowing engine.
The abovc-mcntioncd but not in detail explained filter may fulfil tha same function as the above-discussed heat separatot (2).
A cold separator (3) follows the heat separator (2). This cold separator is by means of any known means cooled to a teuaperatme sufficient for the condensation of the desired fullerene, preferable of a temperature ranging from room temperature up to 200 C_ 2o At the exit of the cold separator (3) generally a powder-like material accumulates oon7Ai*++r-g carbon black with s fisction of the desired fullvre=es of up to d0 %.
Thanks to the lock (12) the carbon black with the accumulated desired fullereacs may be taken from the process and be subjected to further purification. The fiuther purification may be carried out in accordance with a known method, for example by extraction (Dresselbaus et al., Science of Fullerenes and Carbon Nanotubes, Acadcmic Press, 1996, Chapter 5, pp. 111, in particular Chapters 5.2 and 5.3).
The plasma gas coming from the cold separator (3) can be lead back, for example by means of a blowing machine, via the conduit (10) into the plasma reactor (1).
A branch (13) of this conduit (10) allows to guide a part of the cold flow back into the second reaction chamber (B) for cooling the reaction mixture.
The following examples illustrate the subject matter of the invention, howcver, w-ithout limiting it to the scope of the examples.
Examples:
Example 1 The device consists of a cylindrical rcactor with an inner diameter of 300 mm, a height of 150 cm and a double-walled cooling jacket with water circulation.
$etween the graphite lining and the inncc wall of the pressure chamber an isolsting layer of graphite foam is arranged. Three graphite electrodes with a cliaoaetez of 20 mm are positioned with a sliding device through the reactor cover by means of conduit glands inserted into electrically isolating sockets. A
central conduit with a diameter of 3 mm scrvcs for introducing the graphite suspension into the plasmagenic gas. The plasma gas is rure helium kept in a circulation.
The electrodes are supplied with an alternating voltage such that the supplied power is 100 kW.
By a means of a three-phase controller of the type used in an arc furnace comparatively constant electrical properties on the plasma level are achieved.
In this way a plasma temperature of approximately 5000 C is kept in the reaction chamber (A)_ S
The reaction chamber (B) is provided with cold gas guided back to keep its temperature on a value of approximately 1600 T.
The raw material is micronized graphite of the type TZMREXO KS 6 of Timcal Atl. CH-Sins. With an unount of gas of 10 ra3/h on the height of the entrance of the reactor and a material addition of 10 kg/h, a permanent state is achieved after an operating time of 1 hour. In the heat separator (2), kept on a temperature of 800 C, 8 kg/h of non-volatile carbon compounds were separated via the lock (9) and recovered. It was found that approximatcly 6% of the introduced carbon was under these conditions converted into the gaseous fullerene C68. With an effieieney of the heat scparator of approximatcly 90 % the fuliercne C60 was to a small extent mixed with non-volatile carbon compounds and helium. This aerosol was transmitted to the cold scparator (3) kept on a tcmpcrature of 150 C.
2o The product accumulating at the bottom oP the cold separator (3) was during constant opcration removcd from the lock (12) in an amount of 2 kg/h and consisted of 30 % fullerene C60 as a mixture with non-convezted carbon.
The obtained product can in this state be used, however it was further purified according to Dresselbaus et al., Seience of Fullcrcncs and Carbon Nanotubes, Acadcmic Press, 1996, Chapter 5, pp. 111, in particular Chapters 5.2 and 5.3, by extraction with toluol. The exemplary production allows the production of 0.6 kg/h of pure fullerene C6o.
Example 2 The method according to example 1 was repeated, only helium was replaced by argon. Undcr thcsc conditions pure fullerenc C60 could bc obtaincd aftcr purification in the amount of 0.4 kgih.
Example 3 The method according to example 1 was repeated, only the heat separator (2) was rcplaccd by a filter of porous ccramic. The gas flow coming fr+om the filter and entering the cold separator (3) consisted only of helium mixed with gaseous fullerene C60. Thc cfficicncy of the filtcr was approximately 90 %. According to this method pure fullerene C60 could be obtained after purification with an amount of 0.6 kg/h.
Example 4 A method according to example 1 was repeated, only the micronizcd graphite was replaced by a highly pure acetylene black of the company SN2A, F-Berre 1'Etang.
With this mcthod purc fullcrcne C6o with an amount of 0.8 kg/h could bc obtaincd after purification.
Example 5 The method according to example 1 was repeated, only the micronized graphite was rcplaccd by a highly pure, dcgasscd pyrolytic graphitc of the type ENSACO
Super P of the company MMM-Carbon, B-Brussels. With this method pure fullerenc C60 with an amount of 0.7 kg/h could be obtained after purification.
Claims (24)
1. Device for the continuous production of carbon black with a high content of fullerenes from carbon-containing compounds in a plasma consisting of a) a plasma reactor consisting of a first reaction chamber in which two or more electrodes are inserted, wherein the first reaction chamber further includes a supply arrangement for the plasma gas and the carbon-containing compounds to lead the plasma gas and the carbon-containing compounds centrally into a reaction zone, wherein the plasma reactor includes a second reaction chamber adjacent to the first reaction chamber having suitable means for cooling the reaction mixture exiting from the first reaction chamber, b) a heat separator attached to the plasma reactor; and c) a cold separator attached to the heat separator.
2. Device according to claim 1, wherein the plasma reactor is provided with a heat-resistant and heat-isolating lining.
3. Device according to claim 2, wherein the lining consists of graphite.
4. Device according to any one of the claims 1 to 3, wherein the two or more electrodes are arranged with an angle to a longitudinal axis of said first reaction chamber in such a way that they form in the upper part of the first reaction chamber an intersection and that they are individually adjustable in the direction of their own longitudinal axis by means of conduit glands inserted into the first reaction chamber.
5. Device according to claim 4, wherein three electrodes are used, which are operated with a three-phase-alternating voltage and consist of graphite.
6. Device according to any one of the claims 1 to 5, wherein a supply arrangement for plasma gas is provided for cooling.
7. Device according to any one of the claims 1 to 6, wherein the heat separator is provided in the form of an isothermally heatable cyclone, said heat separator comprising in a lower part a lock for the separation of non-volatile compounds and a first heat separator conduit for guiding the non-volatile compounds back into the plasma reactor and a second heat separator conduit in an upper part for guiding volatile compounds into the cold separator.
8. Device according to any one of the claims 1 to 7, wherein the heat separator is provided in the form of a heat-resistant filter.
9. Device according to any one of the claims 1 to 8, wherein the cold separator is provided in the form of a coolable cyclone, said cold separator including in its lower part a lock for the separation of the carbon black containing the fullerenes and in its upper part a cold separator conduit for guiding the plasma gas back into the plasma reactor.
10. Device according to claim 9, wherein a second reaction chamber conduit which is provided as a supply of the plasma gas into the second reaction chamber branches off from the cold separator conduit.
11. Device according to any one of the claims 1 to 10, wherein an entry device for the carbon-containing compounds is present, for feeding the carbon-containing compounds via a lock into a feed conduit.
12. Method for the continuous production of carbon black with a high content of fullerenes wherein carbon-containing compounds in the plasma are converted by means of the device according to any one of the claims 1 to 11.
13. Method according to claim 12 wherein chemically homogenous stable fullerenes are produced.
14. Method according to claim 12 or 13 wherein fullerene C60, C70 or C84 or mixtures of these fullerenes are produced.
15. Method according to any one of the claims 12 to 14 wherein the plasma temperature has a minimal temperature of 4000°C in the first reaction chamber.
16. Method according to any one of the claims 12 to 15 wherein a noble gas or a mixture of different noble gases is used as a plasma gas.
17. Method according to any one of the claims 12 to 16 wherein helium is used as the plasma gas.
18. Method according to any one of the claims 12 to 17 wherein one highly pure carbon or a mixture of highly pure carbons are used as the carbon-containing compounds.
19. Method according to any one of the claims 12 to 18 wherein the temperature in the second reaction chamber is kept at a temperature between 1000°C
to 2700°C.
to 2700°C.
20. Method according to claim 19 wherein the temperature in the second reaction chamber is regulated by the supply of cool plasma gas from a supply device.
21. Method according to any one of the claims 12 to 20 wherein the heat separator is isothermally kept at a temperature of 600°C to 1000°C.
22. Method according to any one of the claims 12 to 21 wherein the cold separator is operated at a temperature ranging from room temperature to 200°C.
23. Method according to any one of the claims 12 to 22 wherein carbon black with a high content of C60 fullerenes is produced.
24. Method according to claim 18 wherein said highly pure carbon or said mixture of highly pure carbons are selected from the group consisting of acetylene black, graphite powder, carbon black, ground pyrolytic graphite and highly calcinated coke.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| FR9707011A FR2764280B1 (en) | 1997-06-06 | 1997-06-06 | PROCESS FOR THE MANUFACTURE OF CARBON 60 |
| FR97/07011 | 1997-06-06 | ||
| PCT/EP1998/003399 WO1998055396A1 (en) | 1997-06-06 | 1998-06-05 | Method and device for producing fullerenes |
Publications (2)
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| CA2293547A1 CA2293547A1 (en) | 1998-12-10 |
| CA2293547C true CA2293547C (en) | 2008-08-05 |
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|---|---|---|---|
| CA002293547A Expired - Fee Related CA2293547C (en) | 1997-06-06 | 1998-06-05 | Method and device for producing fullerenes |
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| EP (1) | EP0991590B1 (en) |
| JP (1) | JP4001212B2 (en) |
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- 1998-06-05 AT AT98934923T patent/ATE240263T1/en not_active IP Right Cessation
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| AU738497B2 (en) | 2001-09-20 |
| EP0991590B1 (en) | 2003-05-14 |
| FR2764280B1 (en) | 1999-07-16 |
| CN1259105A (en) | 2000-07-05 |
| DE59808373D1 (en) | 2003-06-18 |
| PT991590E (en) | 2003-09-30 |
| NO326763B1 (en) | 2009-02-09 |
| ATE240263T1 (en) | 2003-05-15 |
| ES2201513T3 (en) | 2004-03-16 |
| FR2764280A1 (en) | 1998-12-11 |
| NO995970L (en) | 2000-02-04 |
| AU8436898A (en) | 1998-12-21 |
| US6358375B1 (en) | 2002-03-19 |
| NO995970D0 (en) | 1999-12-03 |
| WO1998055396A1 (en) | 1998-12-10 |
| KR20010013476A (en) | 2001-02-26 |
| JP4001212B2 (en) | 2007-10-31 |
| KR100533370B1 (en) | 2005-12-06 |
| EP0991590A1 (en) | 2000-04-12 |
| CA2293547A1 (en) | 1998-12-10 |
| DK0991590T3 (en) | 2003-09-15 |
| CN1113807C (en) | 2003-07-09 |
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