PRODUCTION OF CARBON FILAMENTS IN THE PRESENCE OF IRON MONOXIDE

Abstract: Iron monoxide is produced by treating substantially pure iron with steam at a temperature from at least about 540°C and is used for producing carbon filaments by dissociating a carbon-containing gas at a temperature up to about 800°C.

Description: The present invention relates to the production of FeO and its use in the production of carbon filaments from gaseous hydrocarbons. There is a growing interest in the use of carbon filaments as fillers and reinforcing agents in polymeric compositions. Various methods have been developed for producing such filaments. For example, U.K. Patent No. 1,469,930, teaches that carbon filaments of less than 10 microns length can be grown by the decomposition of acetylene on a catalyst in the form of metal particles carried by an inert substrate. The particles are deposited on the inert substrate, preferably in the form of a thin film. The substrate is taught to be preferably stainless steel in the form of a gauze, although such materials as graphite may be used. Although such a method for producing carbon filaments has its merits, there is still need in the art for producing these filaments more abundantly and efficiently. In accordance with the present invention there is provided a method for preparing iron monoxide (FeO) and using it in the production of carbon filaments. The method of producing FeO comprises (a) heating a metallic iron com- position containing at least 95 wt.% iron, to a temperature of at least about 5400C; (b) contacting the heated iron composition with steam; wherein the iron composition is substantially free of (aa) protective oxide forming elements and (bb) metal components which are volatile at the temperature employed in step (a) above. The carbon filaments are prepared by dissociating a carbon-containing gas in the presence of FeO at a temperature from the dissociation temperature of the carbon-containing gas to about 8000C; wherein the carbon-containing gas is selected from those that will dissociate at a temperature equal to or less than about 8000C, to produce carbon. Carbon-containing gases, preferably hydrocarbon gases, which are suitable for use herein, are those gases which are volatile at the reaction temperatures herein and which will dissociate to produce carbon at temperatures less than about 800 C and at pressures from about 0.5mm to about 760mm Hg. Nonlimiting examples of gases suitable for use herein include carbon monoxide, acetylenes., olefins and paraffins. Preferred are those gases that will produce minimum amounts of amorphous carbon while contributing to maximum growth of filamentous carbon. More preferred are the paraffins and most preferred-are----- the C2 to C4 paraffins. By acetylenes we mean acetylene itself as well as substituted acetylene. It will be understood that the carbon-containing gas suitable for use herein can also be a gas, that is, at temperatures less than about 8000C, will first produce secondary products such as C2 or higher olefins which will subsequently dissociate at those temperatures to give carbon. Furthermore, diluted hydrocarbon streams can be employed if so desired. For example, the hydrocarbon stream can be diluted with an inert gas such as nitrogen or carbon-containing gases such as carbon monoxide and carbon dioxide. In the practice of the present invention, the carbon-containing gas is brought into contact with iron monoxide which catalyzes the growth of carbon filaments. Although, for purposes of producing carbon filaments, it is not critical how iron monoxide is prepared. The preferred method which is the method claimed herein, for producing FeO is to treat an iron composition, preferably comprising at least about 95 wt.% iron with steam at a temperature of at least about 5400C. The iron composition, which more preferably contains at least 98 wt. iron, most preferably substantially pure iron, should be substantially free of (a) protective oxide forming elements such as silicon, chromium, molybdenum, tantalum, and tungsten, and (b) metal components which are volatile at reaction temperatures herein such as cadmium, zinc and lead. The iron containing metal composition which can be used herein for the production of iron monoxide can be in any convenient form. Nonlimiting examples of the form in which the iron composition can be employed include tube, sheet; particle, rod, foil, gauze and a fluidized bed of iron particles. In one preferred embodiment of the present invention, an iron foil, less than about 0.025cm thick is converted to iron monoxide in steam at about 700 to 8000C for about three hours. Although three hours are sufficient in the above case, only an effective amount of time would be required to convert the iron composition to iron monoxide. By effective amount of time we mean that minimum amount of time required to convert the iron composition to iron monoxide to a predetermined depth at the reaction conditions employed. The rate of formation of FeO and the time required to achieve this predetermined depth is, of course, dependent on such factors as temperature and metal composition employed and can be determined by routine experimentation by those having ordinary skill in the art and will not be further elaborated herein. When producing carbon filaments, the flow rate of the carbon-containing gas should be optimized for each gas employed, this can be determined by those having ordinary skill in the art by routine experimentation. Examples of suitable flow rates which can be employed can be found in the examples herein as well as in U.K. Patent No. 1,469,930, - and which teaches a flow rate of 10ml/min to 40ml/min. for acetylene and diolefins when the carbon filament catalyst is a metal particle such as iron. The carbon filaments produced in accordance with the present invention can be employed as strengthening or reinforcing agents, selective adsorption agents, or as catalyst support materials such as for hydrogenation catalysts. Furthermore, the carbon filaments as produced herein will generally have a length of about 1 to 10 microns, although lengths of up to 100 microns are possible. Lengths in excess of 100 microns are usually not obtained because they tend to become detached from the catalyst surface. - The following examples more fully describe the present invention. COMPARATIVE EXAMPLE A Iron foil coupons (99.99% pure) of 0.013cm thickness were cleaned, weighed, and placed in a 2.54cm diameter fused silica reactor tube at room temperature and heated to a temperature of 500"C in flowing (500cc/ min.) nitrogen in a clam shell type electric furnace. Distilled water was then injected in the reactor tube at 0.5cc/min. and the nitrogen flow rate reduced to 50cc/min. The nitrogen used during water injection was to prevent undesirable accumulation of water at the exit of the tube. These conditions were maintained for three hours. Water injection was then cut off and the nitrogen flow rate was increased to 500cc/min., the furnace was turned off and opened to expose the reactor tube to room temperature, thereby ensuring rapid cooling of the samples. Upon reaching room temperature the coupons were re-weighed and the results are shown in Table I below. TABLE I Wt. Before Wt. After Composition of Coupon Coupon Treatment Treatment After Treatment(mmoles) No. (gms) (gms) Fe O 1 0.20591 0.20660 3.68 0.043 2 0.21939 0.21986 3.92 0.029 3 0.19169 0.19191 3.42 0.014 4 0.19595 0.19607 3.50 0.007 Average (normalized) Fe, 1.0; 0, 0.006. The surface composition of the coupons was obtained by the use of Auger Spectroscopy (e.g., Handbook of Auger Electron Spectroscopy, 2nd. Ed., by L.E. Davis, pub. by Physical Electronics Industries Inc., Eden Prairie, Minn. 1976). The atomic composition is readily obtained by measurement of the peak size from the spectra, as the relative sensitivities of iron and oxygen are known. Small samples of the coupon were inserted into the vacuum chamber of the spectrometer. The sample as inserted into the spectrometer is usually slightly contaminated with carbon from the atmosphere, and in the case of the lower oxides of iron, usually excess oxygen. Hence, in all cases the first significant data is obtained after one minute of Ar ion bombardment; during this time, about 15 of the surface is removed by the ions. The spectrum of coupon 4 (in the table) after 150i; of the surface had been removed showed a composition of Fell 30. Further bombardment to a final total time of 25 mins. (about 3800X) showed a continuous drop-off in oxygen content. The final composition of the layer at a depth of 3800 was FeO0 08 This corresponds to 92% Fe, and 8% 0. There is thus no evidence of any formation of near-stoichiometric FeO in the course of this experiment. EXAMPLE 1 The experimental procedure used in Comparative Example A was followed in all respects, except that the water was passed over the coupons for three hours at 5400C. The weight changes of the iron foils are shown in Table II below. TABLE II Wt. Before Wt. After Composition of Coupon Coupon Treatment Treatment After Treatment(mmoles) No. (gms) (gms) Fe O 1 - 0.19514 0.19607 3.49 0.058 2 0.21172 0.21223 3.79 0.032 3 0.19666 0.19721 3.52 0.034 4 0.18729 0.18755 3.35 0.016 Average (normalized Fe, 1.0; 0, 0.010 The surface composition of Coupon No. 2 was analyzed by Auger Spectroscopy and showed a composition of FeOl 00 after bombardment for one minute (150i) and a composition of FeO 94 after bombardment for 30 minutes (4500). Thus, FeO has been produced to a depth of at least 4500A. EXAMPLE 2 The experimental procedure used in Comparative Example A was followed in all respects, except that the water was passed over the coupons for three hours at 5700C. The weight changes of the iron foils are shown in Table III below. TABLE III Wt. Before Wt. After Composition of Coupon Coupon Treatment Treatment After Treatment(mmoles) No. (gms) (gms) Fe o 1 0.19992 0.20062 3.58 0.044 2 0.19396 0.19442 3.47 0.029 3 0.19271 0.19312 3.45 0.026 4 0.21202 0.21258 3.80 0.035 Average (normalized) Fe, 1.0; 0, .009. The surface composition of Coupon No. 2 was also analyzed by Auger Spectroscopy and showed a composition of FeO 82 after bombardment for one minute (150) and a composition of FeO 81 after bombardment for 30 minutes (4500A0) . This shows that FeO has been produced to a depth of at least 4500A. EXAMPLE 3 The experimental procedure used in the above examples was followed except that the water was passed over the coupons for three hours at 6000C. The weight changes of the iron foils are shown in Table IV below. TABLE IV Wt. Before Wt. After Composition of Coupon Coupon Treatment Treatment After Treatment(mmoles) No. (gms) (gms) Fe O 1 0.19450 0.19565 3.48 0.072 2 0.20210 0.20322 3.62 0.070 3 0.19549 0.19659 3.50 0.069 4 0.18487 0.18588 3.31 0.063 Average (normalized) Fe, 1.0; 0, 0.020 The surface composition of Coupon No. 4 was analyzed by Auger Spectroscopy and showed a composition of Fell 07 after bombardment for 12 minutes (1560A) and a composition of FeO 93 after bombardment for 27 minutes (3510A). EXAMPLE 4 The experimental procedure used in the above examples was followed except that the water was passed over the coupons for three hours at 7000C. The weight changes of the iron foils are shown in Table V-below TABLE V Wt. Before Wt. After Composition of Coupon Coupon Treatment 'Treatment After Treatment(mmoles) No. (gms) (gms) Fe O 1 0.20137 0.21077 3.61 0.59 2 0.20126 0.21114 3.60 0.62 3 0.19522 0.20479 3.50 0.60 4 0.19962 0.20947 3.57 ' 0.62 Average (normalized) Fe, 1.0; 0, .170. The surface composition of Coupon No. 4 was analyzed by Auger Spectroscopy and showed a composition of FeOl 14 after bombardment for one minute (138A), a composition of FeO 98 after bombardment for five minutes (690 ), and a composition of FeO 906 after bombardment for 20 minutes (2800i;). EXAMPLE 5 The experimental procedure used in the above examples was followed except that water was initially introduced at 5000C whereupon the coupons were heated to 8000C and held at that temperature for three hours in the presence of water. The weight changes of the iron foils are shown in Table VI below. TABLE VI Wt. Before Wt. After Composition of Coupon Coupon Treatment Treatment After Treatment(mmoles) No. (gms) (gms) Fe O 1 0.20302 0.25095 3.64 3.00 2 0.20987 0.26435 3.76 3.41 3 0.20582 0.24935 3.69 2.72 4 0.20448 0.25409 3.66 3.10 Average (normalized) Fe, 1.0; 0, .83. The surface composition of Coupon No. 4 was analyzed as in the previous examples and showed a composition of Fez 92 after bombardment for one minute (156 ) and a composition of FeO 90 after bombardment for 40 minutes (6200). This example shows that the iron foil coupons were almost totally converted to FeO when treated for three hours at 800 CC in the presence of water. EXAMPLE 6 The experimental procedure used in the above examples was followed except that instead of liquid water being injected into the reactor tube, water vapor was injected by bubbling nitrogen at about 50cc/min., through a reservoir of water. These conditions were maintained at 800"C for a period of three hours. The weight changes of the iron foil coupons are shorn in Table Vil below. TABLE VII Wt. Before Wt. After Composition of Coupon Coupon Treatment Treatment After Treatment-(mmoles) No. (ms) (gms) Fe O 1 0.19844 0.20959 3.55 0.697 2 0.19510 0.20333 3.49 0.514 3 b 0.20016 0.20722 3.58 0.441 4 0.19195 0.19788 3.44 0.371 Average (normalized) Fe, 1.0; 0, .144. The surface composition of Coupon No. 1 was analyzed as in the previous examples and showed a composition of Fe01.32 after bombardment for one minute (130A), a composition of FeO 94 after bombardment for five minutes C (650A), and a composition of FeO gl after bombardment for 30 minutes (3900A). This example demonstrates that at a temperature of at least 8000C lower concentrations of water in the reactor tube are capable of producing FeO to at least a depth of about 4000. EXAMPLE 7 The experimental procedure used in Example 6 above was followed except water vapor was introduced into the reactor at a temperature of 9000C for three hours. The weight changes of the iron foil coupons are shown in Table VIII below. TABLE VIII Wt. Before Wt. After Composition of Coupon Coupon Treatment Treatment After Treatment(mmoles) No. (gms) (gms) Fe O 1 0.19913 0.22340 3.57 1.52 2 0.20872 0.22251 3.74 0.86 3 0.19981 0.20844 3.58 0.54 4 0.18513 0.19394 3.31 0.55 Average (normalized) Fe, 1.0; 0, .244. The surface composition of Coupon No. 1 was analyzed by Auger Spectroscopy and showed a composition of FeOl 21 after bombardment for 3.5 minutes (455 ) a composition of FeOl 06 after bombardment for 20 minutes 126QO ), and a composition of FeO 83 after bombardment for 44.5 C minutes (5800A). In all the above examples, the coupons were cleaned prior to treatment. The cleaning procedure was accomplished by first immersing them in 190 proof ethyl alcohol, followed by treatment in toluene, followed by treatment in ethyl alcohol again, then boiling distilled water, then ethyl alcohol again, and finally dried in air. Comparative Example B Various samples of Foe 203 and Fe were used to catalyze the formation of filamentous carbon in an ethane environment. The Foe 203 samples of known area were in the form of irregularly shaped wafers which were pressed from a powder having a purity of greater than 99.8% Fe203. The Fe samples were cut from a foil having a purity of 99.99% Fe. The size of each Fe sample was about 3cm x 0.6cm and had a thickness of 0.013cm. The Fe samples were cleaned before treatment by first immersing them in 190 proof ethyl alcohol, followed by treatment in toluene, followed by treatment in ethyl alcohol again, then boiling distilled water, then ethyl alcohol again and finally dried in air. All samples were subjected to the same conditions in ethane. Specifically, they were first placed in a fused silica tube in a three zone furnace at room temperature, and heated to a temperature of 7000C, in flowing nitrogen or argon, whereupon the gas mixture was changed to 1% oxygen in nitrogen which was passed through water at ODC, then passed over the samples for five minutes. The tube containing the samples was then flushed with nitrogen for five minutes, whereupon ethane was introduced at a rate of 94cc/min. for a time period from one to six hours, depending on the sample. During this ethane treatment no nitrogen or argon was present. The weight of deposited carbon was determined by comparing the weight of the sample before and after ethane treatment. It is well known in the art that Fe and Foe 203 will form filamentous carbon under the conditions employed herein. Tables I and II below more specifically set forth the conditions employed during ethane treatment for each sample, as well as showing the amount of carbon formed per cm2 of sample. TABLE 1 CARBON FORMATION FROM ETHANE ON Fe Sample Reaction Carbon Formed No. Gas Time (hr) 10 g/cm2 l0 g/cm2/hr 1 N2 2 303.8 151.9 2 Ar 2.5 308.4 139 3 Ar 2 119 59.5 4 Ar 2 232.2 116.1 5 Ar 2 152.8 76.4 6 Ar 3 424.6 141.5 7 Ar 3 326.4 109 8 Ar 1 113.2 113.2 9 N2 1 148.4 148.4 10 Ar 1 109.9 109.9 11 Ar 1 113.3 113.3 12 Ar 1 148.5 148.5 13 Ar 1 77.6 77.6 14 Ar 1 91.8 91.8 Average = 114 TABLE II CARBON FOREIAION FROM ETHANE ON Fe O Carbon Formed Sample Reaction No. Gas Time (hr) 10-4g/cmê 10-4g/cmê/hr 15 N2 2 450 225 16 N2 2 535 267.5 17 N2 2 348 174 18 N2 2 882 441 19* N2 2 526 263 20* N2 2 666 333 21* N2 2 445 222.5 22* N2 2 483 241.5 Average = 271 * These samples did not undergo a 1% oxygen in nitrogen treatment before being treated with ethane. E.xXPLE 8 Five samples of Fe foil, identical to the foil used in Comparative Example B, were oxidized at 800 CC in water to form FeO. Mossbauer Spectroscopy, Auger Spectroscopy and X-ray diffraction techniques were used to verify that FeO was produced. These FeO samples were then subjected to the same procedure, as described in the above comparative example, for treatment with ethane, except for the variations noted in Table III below. TABLE III CARBON FORMATION FROM ETHANE ON FeO Carbon Formed Sample Reaction 4 2 -4 2 No. Gas Time (hr) 10 g/cm 10 g/cm /hr 1 Ar 1 1086 1086 2 Ar 1 1869 1869 3 Ar 1 1129 1129 4 N2 6 8214 1369 5 N2 1 1461.6 1461.6 Average = 1383 Small portions of the carbon produced from these FeO substrates were subsequently oxidized in controlled atmosphere electron microscopy experiments and the carbon was found to be substantially filamentous. A description of controlled atmosphere electron microscopy can be found in Baker, R.T.K., "Carbon Formation on Supported Metal Catalysts", p. 18. in Gas Chemistry in Nuclear Reactors and Large Industrial Plant, edited by A. Dyer, Hedon and Son, Ltd., London 1980. This example, when compared with the above comparative example, illustrates the superior qualities of FeO for catalyzing the formation of filamentous carbon. Furthermore, the reactivity of FeO with respect to filamentous carbon formation is so high that examination of all the FeO samples of this example revealed no trace of the original Fe foil. That is, the entire foil substrate had been completely disintegrated into small particles which were intimately mixed with carbon. Although it had been known that Fe and Fe203 were capable of catalyzing filamentous carbon formation, it had heretofore not been known that such carbon could be formed by way of Feo - let alone at such high rates of formation. Comparative Example C A sample of Fe foil identical to that used in the above examples was cleaned as previously described and placed in a scanning electron microscope and heated from room temperature (about 200C) to 750 CC in the presence of 0.3 Torr flowing acetylene. The sample was held àt 7500C in acetylene until the activity of the Fe for catalyzing the formation of filamentous carbon dropped dramatically. This was determined by continuously analyzing the gaseous effluent from the scanning electron microscope by use of a mass spectrometer. That is, during the formation of filamentous carbon, the acetylene is decomposed and a lower level comes off as effluent, whereas, when the formation of this carbon ceases, the acetylene coming off returns to its original level before reaction began. Analysis of the effluent revealed that carbon formation commenced at about 650 CC and continued for about ten minutes from the time 7500C had been reached. The surface of the substrate was observed before and during treatment. A section of the treated sample was observed by use of a transmission electron microscope and was found that the carbon formed had been entirely filamentous. EXAMPLE 9 A portion of an FeO sample prepared according to the procedure of Example 1 above was placed in a scanning electron microscope under conditions and procedures identical to those described in comparative Example B above. The effluent acetylene level after ten minutes of reaction did not increase nor did it show signs of increasing to its original level after two hours of reaction. This indicated that even after two hours in acetylene the FeO sample was still catalyzing the formation of carbon as opposed to a maximum of ten minutes for Fe. In fact, the reaction was not brought to completion but was terminated at the end of two hours as a matter of convenience. The surface of the treated substrate was observed and was compared to the surface of the sample of Comparative Example B. It was observed that the density of filamentous carbon on the FeO substrate was at least an order of magnitude greater than that of the Fe substrate of Comparative Example B. The surface of the treated FeO substrate was also observed under a transmission electron microscope wherein it was found that substantially all of the carbon was filamentous. Comparative Example D A portion of a Foe 203 wafer as prepared according to Comparative Example A above, was placed in a scanning electron microscope under conditions and procedures identical to those previously described. The behavior of this Foe 203 substrate with respect to filamentous carbon formation was nearly identical to the Fe substrate of Comparative Example B. That is, after about ten minutes of reaction, the level of effluent acetylene was virtually at its original level. Furthermore, as the powder used in preparation of the Fe 203 wafer had a high surface area the reactivity of Fe203 per unit area would be much lower than that of Fe foil. The carbon formed by this Foe 203 substrate was also found to be filamentous. EXAMPLE 10 A portion of the Fe foil and a portion of a FeO substrate as previously described were run side by side in a scanning electron microscope under the identical conditions and procedures as set forth in the previous few examples. The reaction was run for ten minutes after the substrates reached a temperature of 750 CC. The treated substrates were then examined by transmission electron microscopy wherein it was again found that the density of filamentous carbon formed in the FeO substrate was at least an order of magnitude greater than that formed on the Fe substrate.

Claims: CLAIMS: 1. A method for producing iron monoxide which comprises: (a) heating a metallic iron composition, comprising at least about 95 wt.% iron, to a temperature of at least about 5400C; and (b) contacting the heated iron composition with steam; wherein said iron composition is substantially free of (aa) protective oxide forming elements and (bb) metal components which are volatile at the temperature employed in step (a) above. 2. A method according to claim 1 wherein the iron composition contains at least 98 wt.% iron. 3. A method according to either of claims 1 and 2 wherein the temperature employed is from about 550"C to about 900"C. 4. A method according to claim 3 wherein the temperature employed is from about 700 to 800"C. 5. A method for producing carbon filaments comprising dissociating one or more carbon-containing gases in the presence of iron monoxide at a temperature from about the dissociation temperature of the gas to about 8000 C. 6. A method according to claim 5 wherein the carboncontaining gas is carbon monoxide, an acetylene, an olefin, a paraffin or a mixture thereof. 7. A method according to claim 6 wherein the carboncontaining gas is one or more C2 to C4 paraffins. 8. A method according to any one of claims 5 to 7 wherein the temperature employed is from about 700"C to about 800"C. 9. A method according to any one of claims 5 to 8 wherein the iron oxide has been produced by the method according to any one of claims 1 to 4.

Inventors: BAKER, REES TERENCE KEITH, YATES, DAVID JOHN CABENA
Applicants: EXXON RESEARCH AND ENGINEERING COMPANY
Application year: 1982
Main classification: C01G49
IPC codes: C01G49, D01F9