The high-temperature
plasma process has demonstrated great potential
in growing high-quality boron nitride nanotubes (BNNTs) with small
diameters (∼5 nm) and few walls (3–4 walls) and led
to successful commercialization with a high production rate approaching
20 g/h. However, the process is still accompanied by the production
of BN impurities (e.g., a-BN, BN shell, BN flakes)
whose physicochemical properties are similar to those of BNNTs. This
renders the post-purification process very challenging and thus hampers
the development of their practical applications. In this study, we
have employed both experimental and numerical approaches for a mechanistic
understanding of BN impurity formation in the high-temperature plasma
process. This study suggests that the flow structure of the plasma
jet (e.g., laminar or turbulent) plays a key role in the formation
of BN impurities by dictating the transport phenomena of BNNT seeds
(e.g., B droplets), which play an important role in BNNT nucleation.
We discussed that the turbulence enhances the radial diffusion of
B droplets as well as their interparticle coagulation, which leads
to a significant reduction in the population of effective BNNT seeds
in the BNNT growth zone (T < 4000 K). This results
in the generation of unreacted BN precursors (e.g., B-N-H species)
in the BNNT growth zone that eventually self-assemble into BN impurities.
Our numerical simulation also suggests that a higher thermal energy
input makes the flow more turbulent in the BNNT growth zone due to
the elevated velocity difference between the plasma jet and ambient
cold gas. This finding provides critical insight into the process
design that can suppress the BN impurity formation in the high-temperature
plasma process.