Conversion of Methane to Graphite-Like Carbon Nanoparticles Using a Low-Temperature Dusty Plasma

We utilize a dual plasma system to convert methane into graphite-like (turbostratic) carbon particles. A first plasma reactor nucleates seed carbon nanoparticles from precursors such as acetylene or toluene vapor. The seed particles are then injected into a second plasma, supplemented by methane gas. The addition of the seed particles greatly improves the conversion of methane into carbon nanoparticles. We have used the material as a conductive additive in lithium-ion battery anodes and found their performance to be comparable to that of commercial carbon black. This approach is one of the most energy-efficient plasma-based approaches to carbon black synthesis at the laboratory scale.