Current Journal of Applied Science and Technology

Packed-bed reactors are commonly used to measure global kinetic parameters such as conversion, yield, and selectivity in hydrocarbon pyrolysis and catalytic decomposition studies. However, these reactors can suffer from several limitations, such as non-uniform gas residence time, concurrent gas-phase and surface reactions, and potential disruption of deposited carbon structures during post-reaction sampling. This study introduces an alternative approach using a seeded aerosol method, in which carbonaceous catalysts are suspended in a reactive gas stream and subjected to pyrolysis at high temperatures. The resulting carbon aerosols are collected and analysed using transmission electron microscopy (TEM). Results show that the structure of the collected carbon particles is strongly influenced by the initial nanostructure and chemical state of the seed catalyst. This technique offers new insights into the controlled growth of carbon nanomaterials and holds promise for the design of functional carbon blacks with novel morphologies. Combined with ReaxFF simulations, this approach lays the groundwork for the rational design of functional carbon materials with tailored properties. By avoiding the limitations of packed-bed reactors, the method enables direct correlation between catalyst nanostructure and the resulting carbon morphology. The findings suggest that seed-particle reactivity and surface features play crucial roles in carbon deposition.