Self-standing graphene sheets were synthesized using microwave plasmas driven by surface waves at 2.45 GHz stimulating frequency and atmospheric pressure. The method is based on injecting ethanol molecules through a microwave argon plasma environment, where decomposition of ethanol molecules takes place. The evolution of the ethanol decomposition was studied in situ by plasma emission spectroscopy. Free gas-phase carbon atoms created in the plasma diffuse into colder zones, both in radial and axial directions, and aggregate into solid carbon nuclei. The main part of the solid carbon is gradually withdrawn from the hot region of the plasma in the outlet plasma stream where nanostructures assemble and grow. Externally forced heating in the assembly zone of the plasma reactor has been applied to engineer the structural qualities of the assembled nanostructures. The synthesized graphene sheets have been analysed by Raman spectroscopy, scanning electron microscopy, high-resolution transmission electron microscopy and x-ray photoelectron spectroscopy. The presence of sp3 carbons is reduced by increasing the gas temperature in the assembly zone of the plasma reactor. As a general trend, the number of mono-layers decreases when the wall temperature increases from 60 to 100 °C. The synthesized graphene sheets are stable and highly ordered.

One of the greatest challenges in the commercialization of graphene and derivatives is production of high quality material in bulk quantities at low price and in a reproducible manner. The very limited control, or even lack of, over the synthesis process is one of the main problems of conventional approaches. Herein, we present a microwave plasma-enabled scalable route for continuous, large-scale fabrication of free-standing graphene and nitrogen doped graphene sheets. The method’s crucial advantage relies on harnessing unique plasma mechanisms to control the material and energy fluxes of the main building units at the atomic scale. By tailoring the high energy density plasma environment and complementarily applying in situ IR and soft UV radiation, a controllable selective synthesis of high quality graphene sheets at 2 mg/min yield with prescribed structural qualities was achieved. Raman spectroscopy, scanning electron microscopy, high resolution transmission electron microscopy, X-ray photoelectron spectroscopy and Near Edge X-ray-absorption fine-structure spectroscopy were used to probe the morphological, chemical and microstructural features of the produced material. The method described here is scalable and show a potential for controllable, large-scale fabrication of other graphene derivatives and promotes microwave plasmas as a competitive, green, and cost-effective alternative to presently used chemical methods.

A theoretical and experimental study on atmospheric pressure microwave plasma-based assembly of free standing graphene sheets is presented. The synthesis method is based on introducing a carbon-containing precursor (C ₂ H ₅ OH) through a microwave (2.45 GHz) argon plasma environment, where decomposition of ethanol molecules takes place and carbon atoms and molecules are created and then converted into solid carbon nuclei in the ‘colder’ nucleation zones. A theoretical model previously developed has been further updated and refined to map the particle and thermal fluxes in the plasma reactor. Considering the nucleation process as a delicate interplay between thermodynamic and kinetic factors, the model is based on a set of non-linear differential equations describing plasma thermodynamics and chemical kinetics. The model predictions were validated by experimental results. Optical emission spectroscopy was applied to detect the plasma emission related to carbon species from the ‘hot’ plasma zone. Raman spectroscopy, scanning electron microscopy (SEM), and x-ray photoelectron spectroscopy (XPS) techniques have been applied to analyze the synthesized nanostructures. The microstructural features of the solid carbon nuclei collected from the colder zones of plasma reactor vary according to their location. A part of the solid carbon was deposited on the discharge tube wall. The solid assembled from the main stream, which was gradually withdrawn from the hot plasma region in the outlet plasma stream directed to a filter, was composed by ‘flowing’ graphene sheets. The influence of additional hydrogen, Ar flow rate and microwave power on the concentration of obtained stable species and carbon−dicarbon was evaluated. The ratio of sp ³ /sp ² carbons in graphene sheets is presented. A correlation between changes in C ₂ and C number densities and sp ³ /sp ² ratio was found.

An experimental and theoretical study on microwave (2.45 GHz) plasma enabled assembly of carbon nanostructures, such as multilayer graphene sheets and nanoparticles, was performed. The carbon nanostructures were fabricated at different Ar–CH₄ gas mixture composition and flows at atmospheric pressure conditions. The synthesis method is based on decomposition of the carbon-containing precursor (CH₄) in the “hot” microwave plasma environment into carbon atoms and molecules, which are further converted into solid carbon nuclei in the “colder” plasma zones. By tailoring of the plasma environment, a controlled synthesis of graphene sheets and diamond-like nanoparticles was achieved. Selective synthesis of graphene flakes was achieved at a microwave power of 1 kW, Ar and methane flow rates of 600 sccm and 2 sccm respectively, while the predominant synthesis of diamond-like nanoparticles was obtained at the same power, but with higher flow rates, i.e. 1000 and 7.5 sccm, respectively. Optical emission spectroscopy was applied to detect the plasma emission related to carbon species from the ‘hot’ plasma zone and to determine the main plasma parameters. Raman spectroscopy and scanning electron microscopy have been applied to characterize the synthesized nanostructures. A previously developed theoretical model was further updated and employed to understand the mechanism of CH₄ decomposition and formation of the main building units, i.e. C and C₂, of the carbon nanostructures. An insight into the physical chemistry of carbon nanostructure formation in a high energy density microwave plasma environment is presented.

Microwave atmospheric pressure plasmas driven by surface waves were used to synthesize graphene sheets from vaporized ethanol molecules carried through argon plasma. In the plasma, ethanol decomposes creating carbon atoms that form nanostructures in the outlet plasma stream, where external cooling/heating was applied. It was found that the outlet gas stream temperature plays an important role in the nucleation processes and the structural quality of the produced nanostructures. The synthesis of few layers (from one to five) graphene has been confirmed by high-resolution transmission electron microscopy. Raman spectral studies were conducted to determine the ratio of the 2D to G peaks (>2). Disorder D-peak to G-peak intensity ratio decreases when outlet gas stream temperature decreases.

Free-standing N-graphene was synthesized using a microwave plasma-based method at atmospheric pressure conditions through a single step and in a controllable manner. Using ethanol and ammonia as precursors, N-graphene with low relative amount of bonded oxygen and low level of saturated sp³ carbon bonds was produced. Adjusting the injection position of the nitrogen precursor in the plasma medium leads to selectivity in terms of doping level, nitrogen configuration and production yield. A previously developed theoretical model, based on plasma thermodynamics and chemical kinetics, was further updated to account for the presence of nitrogen precursor. The important role of HCN attachment to the graphene sheets as the main process of N-graphene formation is elucidated. The model predictions were validated by experimental results. Optical Emission Spectroscopy was used to detect the emission of plasma generated “building units” and to determine the gas temperature. The plasma outlet gas was analyzed by Fourier-Transform Infrared Spectroscopy to detect the generated gaseous by-products. The synthesized N-graphene was characterized by Scanning Electron Microscopy, Raman and X-ray photoelectron spectroscopies.