Single-walled carbon nanotube catalysts and methods for preparing same

Abstract

An activated catalyst capable of selectively growing single-walled carbon nanotubes when reacted with carbonaceous gas is provided. The activated catalyst is formed by reducing a catalyst that comprises a complex oxide. The complex oxide may be of formula A x−w F w B y−v G v O z wherein x/y≦2; z/y≦4; 0≦w≦0.3x; 0≦v≦0.3y; A is a Group VIII element; F is an element that is different from A but has, in said composition, the same valence state as A; B is an element different from A and F, and is an element whose simple oxide, in which B is at the same valence state as in the complex oxide, is not reducible in the presence of hydrogen gas at a temperature less than about 900° C.; G is an element different from A, B and F, and is an element whose simple oxide, in which G is at the same valence state as in the complex oxide, is not reducible in the presence of hydrogen gas at a temperature less than about 900° C.; and O is oxygen. The complex oxide is reduced at a temperature less that 950° C. Methods of making, uses for and carbon fibril-containing product made with these activated catalysts are also provided.

1 - 22 . (canceled) 
     
     
         23 . A method of making a catalyst for use in a process for the manufacture of single walled carbon nanotubes comprising the steps of:
 reacting a source of A, F, B, and G together at a temperature sufficiently low so as to form a complex oxide having a formula
   A x−w F w B y−v G v O z   
   wherein
 x/y≦2; 
 z/y≦4; 
 0≦w≦0.3x; 
 0≦v≦0.3y; 
 A is a Group VIII element; 
 F is an element that is different from A but has, in said composition, the same valence state as A; 
 B is an element different from A and F, and is an element whose simple oxide, in which B is at the same valence state as in the complex oxide, is not reducible in the presence of hydrogen gas at a temperature less than about 900° C.; 
 G is an element different from A, B and F, and is an element whose simple oxide, in which G is at the same valence state as in the complex oxide, is not reducible in the presence of hydrogen gas at a temperature less than about 900° C.; 
 o is oxygen; and 
   activating the complex oxide by reducing said complex oxide at a temperature less than about 950° C.   
     
     
         24 . A method of making a catalyst for use in a process for the manufacture of single walled carbon nanotubes comprising the step of reducing a complex oxide of formula A x−w F w B y−v G v O z  at a temperature less that 950° C., wherein
 x/y≦2;   z/y≦4;   0≦w≦0.3x;   0≦v≦0.3y;   A is a Group VIII element;   F is an element that is different from A but has, in said composition, the same valence state as A;   B is an element different from A and F, and is an element whose simple oxide, in which B is at the same valence state as in the complex oxide, is not reducible in the presence of hydrogen gas at a temperature less than about 900° C.;   G is an element different from A, B and F, and is an element whose simple oxide, in which G is at the same valence state as in the complex oxide, is not reducible in the presence of hydrogen gas at a temperature less than about 900° C.; and   O is oxygen.   
     
     
         25 . A catalyst manufactured by the method of  claim 23 . 
     
     
         26 . A catalyst manufactured by the method of  claim 24 .