Carbon source precursors for high-grade, clean, and low-carbon refractories were obtained by in situ exfoliation of flake graphite (FG) and phenol-formaldehyde resin (PF) composites with three-roll milling (TRM) for the fabrication of graphite nanoplatelets. In addition, by using Ni(NO3)2·6H2O as a catalyst in the pyrolysis process, multidimensional carbon nanostructures were obtained with coexisting graphite nanoplatelets (GNPs), glassy carbon (GC), and carbon nanotubes (CNTs). The resulting GNPs (exfoliated 16 times) had sizes of 10-30 μm, thicknesses of 30-50 nm, and could be uniformly dispersed in GC from the PF pyrolysis. Moreover, Ni(NO3)2·6H2O played a key role in the formation and growth of CNTs from a catalytic pyrolysis of partial PF with the V-S/tip growth mechanisms. The resulting multidimensional carbon nanostructures with GNPs/GC/CNTs are attributed to the shear force of the TRM process, pyrolysis, and catalytic action of nitrates. This method reduced the production costs of carbon source precursors for low-carbon refractories, and the precursors exhibited excellent performances when fabricated on large scales.
Keywords: catalytic growth of CNTs; multidimensional nanocarbon structures; nanoplatelets exfoliated from graphite; phenol-formaldehyde resin; three-roll milling.