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This research endeavours to study the growth of ultralong carbon nanotubes (UL-CNTs) from methane using diverse catalysts, namely FeCl3, bi-metallic Fe-Cu, Fe-Ni, and Fe-Co chlorides. Aqueous catalyst solutions were evenly dispersed on silica substrates and grown at 950 °C in the presence of hydrogen via a horizontal chemical vapour deposition (CVD) furnace. The samples underwent characterisation by Raman spectroscopy, scanning electron microscopy (SEM), and optical microscopy to identify the quality of CNTs and enumerate individual UL-CNTs. Our findings revealed that FeCl3, as a mono-metallic catalyst, generated the longest UL-CNTs, which measured 1.32 cm, followed by Fe-Cu (0.85 cm), Fe-Co (0.7 cm), and Fe-Ni (0.6 cm), respectively. The G/D ratio (graphene to defects) from the Raman spectroscopy was the highest with the FeCl3 catalyst (3.09), followed by Fe-Cu (2.79), Fe-Co catalyst (2.13), and Fe-Ni (2.52). It indicates that the mono-iron-based catalyst also produces the highest purity CNTs. Moreover, this study scrutinises the vapour-liquid-solid (VLS) model for CNT growth and the impact of carbide formation as a precursor to CNT growth. Our research findings indicate that forming iron carbide (Fe3C) is a crucial transition phase for amorphous carbon transformation to CNTs. Notably, the iron catalyst generated the longest and densest CNTs relative to other iron-based bi-metallic catalysts, which is consistent with the temperature of carbide formation in the mono-metallic system. From correlations made using the phase diagram with carbon, we conclude that CNT growth is favoured because of increased carbon solubility within the mono-metallic catalyst compared to the bi-metallic catalysts. [ABSTRACT FROM AUTHOR]

For every three people on the planet, there are approximately two Tonnes (Te) of plastic waste. We show that carbon recovery from polystyrene (PS) plastic is enhanced by the coaddition of solvents to grow carbon nanotubes (CNTs) by liquid injection chemical vapour deposition. Polystyrene was loaded up to 4 wt% in toluene and heated to 780 °C in the presence of a ferrocene catalyst and a hydrogen/argon carrier gas at a 1:19 ratio. High resolution transmission electron microscopy (HRTEM), scanning electron microscopy (SEM), thermogravimetric analysis (TGA) and Raman spectroscopy were used to identify multiwalled carbon nanotubes (MWCNTs). The PS addition in the range from 0 to 4 wt% showed improved quality and CNT homogeneity; Raman "Graphitic/Defective" (G/D) values increased from 1.9 to 2.3; mean CNT diameters increased from 43.0 to 49.2 nm; and maximum CNT yield increased from 11.37% to 14.31%. Since both the CNT diameters and the percentage yield increased following the addition of polystyrene, we conclude that carbon from PS contributes to the carbon within the MWCNTs. The electrical contact resistance of acid-washed Bucky papers produced from each loading ranged from 2.2 to 4.4 Ohm, with no direct correlation to PS loading. Due to this narrow range, materials with different loadings were mixed to create the six wires of an Ethernet cable and tested using iPerf3; the cable achieved up- and down- link speeds of ~99.5 Mbps, i.e., comparable to Cu wire with the same dimensions (~99.5 Mbps). The lifecycle assessment (LCA) of CNT wire production was compared to copper wire production for a use case in a Boeing 747-400 over the lifespan of the aircraft. Due to their lightweight nature, the CNT wires decreased the CO2 footprint by 21 kTonnes (kTe) over the aircraft's lifespan. [ABSTRACT FROM AUTHOR]