Design methodology for fluidized bed carbon nanotube synthesis

Carbon nanotubes constitute a unique class of carbon materials with exceptional mechanical and thermal properties by virtue of which significant breakthroughs have been possible in various fields. The increasing breadth of applications necessitates the mass production of high-quality nanotubes and a viable technology to accomplish the same. Fluidized bed technology has demonstrated significant potential to cater to high-volume nanotube production by virtue of its benefits such as isothermal operation with high heat and mass transfer rates. A suitable design approach for the fluidized bed reactor is necessary to realize its manifold advantages. The present paper proposes an organized methodology for the design of a fluidized bed synthesis of carbon nanotubes by taking into consideration the complex hydrodynamics and the diffusion of carbon into the nanosized iron catalyst to nucleate nanotubes. The authors further extend the calculations to the design of a perforated gas distributor to ensure uniform fluidization so as to enhance mass transfer to the catalyst support. The authors present typical results obtained using the methodology for nanotube synthesis and depict the distributor design for the same.