Method of producing vapor grown carbon fibers using coal
AssigneeApplied Sciences, Inc.
InventorsRobert L. Alig, David J. Burton
Life of this patent
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Abstract
A method of producing vapor grown carbon fibers is provided in which coal is utilized as a source of an iron catalyst, as a source of hydrocarbon and sulfur, or both. The method includes the steps of introducing pulverized coal into a furnace containing a gas selected from the group consisting of hydrogen, hydrocarbon, nitrogen, ammonia, helium, or mixtures thereof, and maintaining the gas at a temperature from about 1000.degree.-1175.degree. C. to form the fibers. The coal has a sulfur content of from 1 to 6% by weight and may comprise high volatile bituminous coal. The use of coal to produce vapor grown carbon fibers provides a significant cost advantage over other starting materials and also provides an environmentally safe use for high sulfur content coal.
Claims15
A method of making vapor grown carbon fibers comprising the steps of:
- introducing pulverized coal containing from about 0.5% to 2.25% by weight iron disulfide into a reactor furnace containing a gas selected from the group consisting of hydrogen, methane or a mixture thereof comprising from about 0.1 to 99.9% hydrogen gas and from about 0.1 to 99.95 methane gas, such that said coal becomes mixed with said gas and establishes a molar ratio of carbon to iron in said mixture of from about 600:1 to 1000:1 and a molar ratio of sulfur to iron in said mixture of from about 0.5:1 to 12:1;
- wherein said coal functions as a catalyst for fiber nucleation and growth;
- maintaining said gas at a sufficient temperature to form vapor grown carbon fibers;
- and
- collecting said fibers from the exhaust stream of said furnace.
A method of making vapor grown carbon fibers comprising the steps of:
- introducing pulverized coal into a reactor furnace containing a gas selected from the group consisting of hydrogen, hydrocarbon, nitrogen, ammonia, helium or mixtures thereof such that said coal becomes mixed with said gas, wherein said coal is a source of hydrocarbon and sulfur;
- adding a catalyst comprising iron pentacarbonyl for fiber nucleation and growth to establish a molar ratio of carbon to iron in said mixture of from about 600:1 to 1000:1 and a molar ratio of sulfur to iron in said mixture of from about 0.5:1 to 12:1;
- maintaining said gas at a sufficient temperature to form vapor grown carbon fibers;
- and
- collecting said fibers from the exhaust stream of said furnace.
A method of making vapor grown carbon fibers comprising the steps of:
- introducing pulverized coal into a reactor furnace containing a gas selected from the group consisting of hydrogen, hydrocarbon, nitrogen, ammonia, helium or mixtures thereof such that said coal becomes mixed with said gas, said reactor furnace including a tangential burner connected thereto to prevent fiber and ash build-up on the walls of said furnace during formation of said fibers;
- adding other ingredients necessary to establish a molar ratio of carbon to iron in said mixture of from about 600:1 to 1000:1 and a molar ratio of sulfur to iron in said mixture of from about 0.5:1 to 12:1;
- maintaining said gas at a sufficient temperature to form vapor grown carbon fibers;
- and
- collecting said fibers from the exhaust stream of said furnace.
Dependencies are inferred from the claim text.