Floating Catalyst Reactor Design and Safety Features for Carbon Nanotube Synthesis

Abstract The floating catalyst gas-phase pyrolysis method has been an important method to synthesize carbon nanotube sheet. Its advantage over other chemical vapor deposition methods is due to its continuous synthesis process and the potential for scaling up. Industries have already adopted this method to produce commercial products for various applications. But the synthesis process itself is time-consuming, and the high-temperature environment and use of explosive gases have hampered the practicality of daily-based activities for small-scale and research-oriented users. In this article, reactor design and several safety issues associated with this method will be addressed, and modifications will be discussed.