Novel method of carbon coating

Abstract

The invention discloses a method of preparing a colloid liquid for carbonisation, comprising the following steps: - Heating a sucrose to a first temperature range, in which the sucrose melts; - Heating the sucrose to a second temperature range, in which the sucrose is at least partially carbonised, wherein the temperature of the second temperature range is higher than the temperature of the first temperature range; and - Directing a superheated steam or water on the melted and at least partially carbonised sucrose; and a method of carbonating a substrate comprising the following steps: - Impregnate the substrate with the colloid liquid, and - Sintering the substrate.

Description

[0001] Title

[0002] Novel method of carbon coating

[0003] Description

[0004] Field of the Invention

[0005] The present invention relates to carbon coating, particularly to carbon coating of porous and microcellular substances (e.g. chalk, soft limestone, zeolite, etc.).

[0006] The present invention encompasses the production of nano-coating materials, their application, and the associated processes.

[0007] Related Art

[0008] Creating a liquid coating according to methods of the prior art for microcellular substances using carbon or coal involves suspending finely ground coal particles in a liquid medium along with any necessary additives or binders.

[0009] In a first step, a liquid medium is chosen that is compatible with both the microcellular substance and the coal particles. Standard options include water, organic solvents, or specialty coatings formulated for this purpose. The liquid medium should have properties that facilitate the suspension of coal particles while allowing for easy application and subsequent drying.

[0010] In a second step, the coal is ground into a fine powder. The finer the particles, the better they will disperse and adhere to the microcellular substance. Optionally, treat the coal powder with surface modifiers or dispersants to improve its suspension properties in the liquid medium.

[0011] In a third step, the desired quantity of liquid medium is metered into a suitable container. Gradually, the finely ground coal powder is added continuously to the fluid medium while it is being stirred. Thorough mixing is necessary to achieve a homogeneous suspension of coal particles in the liquid. Optionally, binders, dispersants or other additives may be added to improve adhesion, stability or other desired properties of the coating.

[0012] In the fourth step, the coating liquid is applied to the surface of the microcellular substance using a suitable method, such as spraying, brushing, dipping, or rolling. Even coverage of the surface with the coating liquid must be achieved to obtain a uniform coating thickness.

[0013] Thereafter, the coated microcellular substance must dry thoroughly to remove the liquid medium and any volatile components.

[0014] In the prior art, the cleanest carbons can be produced by thermally treating the sucrose (C12H22O11). Coal production in this manner is expensive, and grinding it into nano-particles is also particularly costly. Impregnation is followed by drying, and the nano-particles remain in the microcell structure. The bond between the substrate and the nano-carbon is weak, and segregation is very possible. Therefore, binding additives are generally used in this technology. With this technology, the nanocarbon powder can obstruct the cellular microstructure. With this technology, the carbon coating of the entire cross-action is difficult.

[0015] General Description of the Invention

[0016] It is an object of the present invention to overcome the disadvantages of the prior art and to provide a more economic method of nano-carbon coating.

[0017] The object of the present invention is achieved by a method of preparing a colloid liquid for carbonisation according to claim 1 and a method of carbonating a substrate according to claim 6.

[0018] The present invention discloses a method of preparing a colloid liquid for carbonisation. In the first step, sucrose is heated to a specific temperature range to remove its crystal water content and in which the sucrose is melted. The method further comprises the step of heating the sucrose to a second temperature range, in which the sucrose is at least partially carbonised, where the temperature of the second temperature range is higher than that of the first temperature range.

[0019] Preferably the sucrose is merely partially carbonised. The process further comprises the step of passing superheated steam or water into the melted and at least partially carbonised sucrose. According to the invention, the nano-carbon particles are (mainly) formed by carbonisation of the sucrose after melting and dehydration thereof.

[0020] The sucrose (C12H22O11) may be a sugar, such as sugar from cane or beet root. Thereby, nano carbon contamination can be avoided.

[0021] The first temperature range may be between 180°C and 190°C. The second temperature range may be between 220°C and 230°C. There are two phases of heating: firstly, melting and loss of crystal water at 180°C and 190°C, and secondly, carbonisation at 220°C to 230°C.

[0022] The temperature of the superheated steam may be below 230°C. In one embodiment, water or boiled water can be used, which is poured into the sucrose heated to 220-230 °C. The process can also be carried out under pressure. The lower the temperature difference between the carbonised sucrose and the steam (water), the faster the nano-carbon dissolves and the colloidal liquid is formed.

[0023] The invention also discloses a method of carbonating a substrate, comprising the steps of impregnating the substrate with the above-described colloid liquid and sintering the substrate. The substrate is coated with nano-carbon particles by impregnating and sintering.

[0024] The step of sintering the substrate may comprise the step of pre-sintering the substrate in a third temperature range and the step of post-sintering the substrate in a fourth temperature range, wherein the temperature of the fourth temperature range is higher than that of the third temperature range. The substrate is coated with nanocarbon particles through impregnation, pre-sintering, and / or post-sintering.

[0025] In one embodiment, pre-sintering and post-sintering may be carried out in a single step.

[0026] The third temperature range may range from 150°C to 250°C.

[0027] The fourth temperature range may range from 250°C to 400°C.

[0028] The step of post-sintering the substrate in a fourth temperature range may be carried out in an inert gas atmosphere.

[0029] The method may comprise the step of adding an anticoagulant additive to the colloid liquid. A suitable anticoagulant may include a magnesium compound with a concentration of approximately 1 % or more.

[0030] The substrate may be a microcellular structure. The microcellular structure may comprise a material with a porous and microcellular structure, such as soft limestone, chalk, zeolite, silica gel, etc. The substrate coated with the nano-carbon layer according to the present invention is a good bacterial carrier. With this bacterial carrier, the seed can be coated, or the substrate forming the bacterial carrier may be placed close to the seed.

[0031] The invention also discloses a substrate coated with nano-carbon by the above method.

[0032] The invention also discloses a seed covered with the coated substrate.

[0033] Detailed description of the Invention

[0034] Sucrose (C12H22O11), which cannot undergo fermentation before inversion, is used to create the colloid fluid. Initially, the sucrose loses its crystal water content through heating in a boiler. The boiler is an open vessel with normal pressure and not filled with inert gas. To prevent combustion damage, fluidised bed heat transfer is preferred in the boiler. Subsequent heating within the range of 180°C to 230°C transforms the sucrose into nano-carbon. However, before the solid state is reached, the nano-carbon is converted into a liquid state using superheated steam or water. In case the carbonisation of sucrose reached the solid state, it would be complicated to form a colloidal liquid with steam or water. In this step of the technology, the superheated steam does not increase the temperature of the system; instead, it serves to accelerate the formation of the colloidal liquid. The nano-carbon particles within the colloidal liquid exhibit Brownian motion, allowing them to remain suspended without sedimentation. The processed colloid liquid is stable, nonflammable, and frost-resistant when undiluted.

[0035] The invention discloses the formulation and preparation of a specific colloid liquid suitable for the subsequent carbonisation process described earlier. This colloidal liquid serves as a critical component in achieving a successful nano-carbon coating.

[0036] The porous and microcellular material, i.e. substrate, must be impregnated with the colloidal liquid. In one embodiment, this can be achieved through immersion or vacuum methods, ensuring thorough saturation of the porous and microcellular material. Several factors influence the impregnation process, including the cell structure of the porous and microcellular material, the temperature of both the substrate (porous and microcellular material) and the colloid liquid, which should, in one embodiment, not exceed 250°C, and the dilution level of the colloid liquid.

[0037] In one embodiment, the impregnated material undergoes pre-sintering followed by final sintering. During pre-sintering, preferably within the range of 150°C to 250°C, the water that acts as the carrier material for nano-carbon particles must be vaporised using an appropriate drying system. Rotary kilns or simply heated conveyor belts may be used for the drying process.

[0038] The final sintering occurs at temperatures between 250°C and 400°C, converting all hydrocarbons into nano-carbon by the following reaction: C12H22O11 -> 12 C + 11 H2O.

[0039] To prevent nano-carbon combustion, the post-sintering process takes place in a closed rotary oven with an external heating system, utilising an inert gas atmosphere. Without the use of inert gas, carbon dioxide and carbon monoxide are produced during the final sintering stage.

[0040] The process, as described in the present invention, involves applying a colloidal liquid containing nano-carbon to a substrate. The final sintering process converts all hydrocarbons into nano-carbon, resulting in the desired coating.

[0041] In one embodiment, it is possible to combine pre-sintering and final sintering into a single step.

[0042] Diluting the colloid liquid allows precise adjustment of the nano-carbon content within the substrate.

[0043] The substrate may vary in size, from fine powder to several-centimetre pieces.

[0044] Depending on the colloidal liquid’s dilution, the granulation of the substrate is affected. The colloidal liquid serves a dual purpose, namely, impregnating the substrate and binding small particles of the powder. The colloidal liquid not only impregnates the substrate but also binds the small particles of the powder, allowing for granulation.

[0045] The granulation effect can also be regulated by the addition of an anticoagulant, such as a magnesium compound, with a concentration of approximately 1 % or higher.

[0046] Large carbonised substrate pieces (several centimetres in size) can be ground to achieve any desired particle size. The coated substrate may be utilised in various fields, including agriculture, construction, filter technology, soil reclamation, soil conditioning, water treatment, the healthcare industry, and other relevant areas. Its unique properties make it suitable for specific applications within these domains.

[0047] The carbonisation process, as described in the present invention, can be applied to create materials for use in floating and sedimentary particle applications.

[0048] According to the invention, the nano-carbon particles are (mainly) formed by carbonisation of the sucrose after melting and dehydration thereof.

[0049] The method according to the present invention achieves an economical carbon coating of porous and microcellular materials. The colloidal liquid produced from sucrose before final sintering contains not only pure carbon particles but also specific hydrocarbons. These hydrocarbons transform into nano-carbon during the final sintering process, creating a strong bond between the microcellular material and the nano-particles. The technology provides a carbon coating over the entire crosssection of the substrate.

[0050] According to the present invention, carbon is formed, which is refined during the final heat treatment.

[0051] The pH value of the nano-carbon is inherited from the substrate; in the case of the soft limestone substrate (chalk substrate), the pH value is 8 to 8.5. The water absorption is inherited from the substrate and reduced by the nano-carbon coating.

[0052] The nano-carbon coating has disinfecting properties.

[0053] A soft limestone (chalk) coated with nano-carbon was left in water for two weeks, and there were no dissolved substances from either the colloidal components or the soft limestone. The advantage of the present invention is that the substrate coated with nanocarbon according to the present invention serves as a good bacterial carrier. With this bacterial carrier, the seed can be coated, or the substrate forming the bacterial carrier may be placed close to the seed.

Claims

1. CLAIMS1. A method of preparing a colloid liquid for carbonisation, comprising the following steps:- Heating sucrose to a first temperature range, in which sucrose melts and loses its crystal water content;- Heating sucrose to a second temperature range, in which sucrose is at least partially carbonised, wherein the temperature of the second temperature range is higher than the temperature of the first temperature range; and- Directing a superheated steam or water on melted and at least partially carbonised sucrose.

2. The method of claim 1 , wherein the sucrose is C12H22O11.

3. The method of claim 1 or 2, wherein the first temperature range is between 180°C and 190°C.

4. The method according to any one of claims 1 to 3, wherein the second temperature range is between 220°C and 230°C.

5. The method according to any one of claims 1 to 4, wherein the temperature of the superheated stream is a maximum of 230°C.

6. A method of carbonating a substrate comprising the following steps:- Impregnate the substrate with the colloid liquid made by any one of claims 1 to 5; and- Sintering the substrate.

7. The method according to claim 6, wherein the step of sintering the substrate comprises the step of- Pre-sintering the substrate in a third temperature range; andPost-sintering the substrate in a fourth temperature range, wherein the temperature of the fourth temperature range is higher than the temperature of the third temperature range.

8. The method according to claim 6 or 7, wherein the third temperature range ranges from 150°C to 250°C.

9. The method according to any one of claims 6 to 8, wherein the fourth temperature range ranges from 250°C to 400°C.

10. The method according to any one of claims 6 to 9, wherein the step of postsintering the substrate in a fourth temperature range is carried out in an inert gas atmosphere.11 . The method according to any one of claims 6 to 10, further comprising the step of adding an anticoagulant additive to the colloid liquid.

12. The method according to any one of claims 6 to 11 , wherein the substrate is a microcellular structure.

13. A substrate coated with nano-carbon by a method according to any one of claims 6 to 12.

14. A seed covered with the coated substrate according to claim 13.