Process for producing graphene from captured carbon dioxide by using hybrid alkaline system

Abstract

The present invention relates to a system for carbon dioxide capture and utilization using an alkaline ceramic media (ACM) as medium for CO₂ adsorption from sources in the industry, for example, exhaust gas from manufacturing process in the industry, where the ACM has the high pH, which can capture the CO₂ efficiently, and durable to carbonic acid formation from the reaction between CO₂ and water. Moreover, the system can use the captured CO₂ for process in producing graphene, suitable for in the energy and electronic industries. The system uses the a nanoplatelet activated carbon produced from biomass, having a high surface area to enhance CO₂ adsorption. The nano porous structure also assists the system to capture CO₂ efficiently and sustainably. The graphene from CO₂ via the converting process in the specific reactor can be used in various industries and increase the value-added to the captured CO₂ by using the system design worthy and using the materials available in the biomass, which is low cost and environmentally friendly.

Description

[0001] PROCESS FOR PRODUCING GRAPHENE FROM CAPTURED CARBON DIOXIDE

[0002] BY USING HYBRID ALKALINE SYSTEM

[0003] Field of the invention

[0004] Material, engineering, and environmental science, especially related to the process for producing graphene from captured carbon dioxide by using hybrid alkaline system. of the invention

[0005] Climate change has become one of the most critical global issues, with greenhouse gas emissions, particularly carbon dioxide (CO2), being the main contributor to global warming. Therefore, the development of technologies that can help reduce CO2 emissions is of great importance. Carbon Capture, Utilization, and Storage (CCUS) technologies have been extensively developed over the past few decades with the aim of reducing the amount of CO2 released into the atmosphere. One carbon sequestration approach that has recently gained significant attention is the use of alkaline ceramic media (ACM), which is high alkalinity property materials with excellent CO2 adsorption capacity. These ACM can react with CO2 to produce stable carbonate compounds. The use of ACM enables the adsorption and storage of CO2 in a way that is applicable to industrial processes. A notable example is the conversion of CO2 into graphene, a material known for its exceptional properties such as high strength, durability, and outstanding electrical conductivity. Moreover, the graphene derived from CO2 can be utilized across various industries, including energy, electronics, and materials requiring high mechanical strength. This conversion not only adds economic value but also promotes the sustainable utilization of CO2. Researches in material science and nanotechnology has played a key role in developing the system, improving the of CO2 adsorption efficiency in an environmentally friendly manner, and reducing the production cost of graphene for industrial applications.

[0006] Research over the past decade has focused on technologies for carbon storage and utilization. Carbon Capture, Utilization, and Storage (CCUS) encompasses the development of materials with high CO2 absorption properties, particularly alkaline ceramic materials designed to enhance the efficiency of carbon capture from various sources, such as exhaust gases from industrial plants. The researches on alkaline ceramic media (ACM) have demonstrated their effectiveness in CO2 adsorption. These materials can withstand reactions with carbonic acid, formed CO2 reacts with water, allowing them to maintain a high pH value. This characteristic gives alkaline ceramics strong potential for more sustainable and efficient carbon capture. Current research in nanomaterials and materials science has found that graphene, derived from captured CO2, possesses a durable structure, excellent electrical conductivity, and high mechanical strength. These properties make graphene suitable for use in industries such as energy, electronics, and advanced materials manufacturing. Its high conductivity and strength are particularly valuable in applications like energy storage devices and batteries. Research from Texas A&M University suggests that developing graphene from captured CO2 could help reduce greenhouse gas emissions while creating high-value products. Several patents have been filed related to CO2 capture and utilization, especially those involving alkaline ceramics for CO2 adsorption and conversion into graphene. One notable example is a patent from Corning Inc., which developed a honeycomb -structured ceramic for use in CO2 capture systems, including Direct Air Capture (DAC) and point-source capture. These ceramics are designed with high surface area and mechanical strength, enabling efficient CO2 capture and forming a foundation for broader CCUS applications. Additionally, patented technologies for biomass-derived carbon capture focus on using nanostructured materials, such as nanoplatelet activated carbon, for efficient CO2 adsorption. These innovations not only reduce biomass waste but also increase surface area and lower the cost of CO2 capture processes. Patents related to the conversion of CO2 into valuable materials like graphene highlight its potential in various industries, including energy production, electronics, and structural materials requiring high durability and conductivity. For example, graphene is being explored for use in energy storage devices and conductive structural components. These developments indicate that CO2 capture and utilization technologies, particularly those involving graphene conversion, are gaining global attention. Future trends point toward scalable, cost-effective carbon capture systems that offer sustainable solutions for reducing greenhouse gas emissions.

[0007] The motivation for developing this invention is from the need to address greenhouse gas emissions, a major driver of global warming. Industrial carbon dioxide (CO2) emissions are among the primary contributors to climate change. CCUS systems are often costly and have limited efficiency, particularly when it comes to utilizing CO2 as a resource to produce valuable materials rather than merely storing it. Converting CO2 into graphene, which is a material known for its exceptional electrical conductivity, high strength, and durability, offers a promising approach that not only reduces CO2 emissions but also adds economic value and opens new opportunities across various industries, including energy, electronics, and advanced materials. This invention is unique and differs from conventional carbon capture technologies in several key aspects including: (1) high CO2 capture efficiency: The use of alkaline ceramic media with a high pH value enhances CO2 adsorption efficiency compared to conventional adsorbents. These ceramics are also resistant to carbonic acid reactions, resulting in a longer operational lifespan; (2) CO2 utilization for graphene production: Instead of simply storing captured CO2, this system converts it into graphene, a high-value material used in energy devices, electronics, and other high-performance applications. This approach not only mitigates emissions but also generates sustainable economic benefits, and (3) low cost and sustainability: The system utilizes readily available materials, potentially derived from industrial or agricultural biomass waste. This reduces production costs and supports environmental sustainability.

[0008] The development of innovative alkaline ceramics for carbon capture and the conversion of CO2 into graphene represents a forward-looking solution that meets the evolving needs of modern industries. This technology aligns with global efforts to reduce greenhouse gas emissions and supports the long-term goal of achieving carbon neutrality. of the invention

[0009] This invention is directly related to the development of ceramic alkaline system for carbon storage and utilization, which focuses on the use of ceramic alkaline with high pH having CO2 adsorption from industrial source, for example, exhaust gas from manufacturing process. Such the ceramic alkaline is designed to be resistant to carbonic acid within the system, which can maintain the alkalinity, and sustainably enhance the CO2 adsorption. Moreover, this invention also has the step of captured CO2 transformation to graphene which has strongly chemical and physical properties, for example, high strength, high electrical conductivity, and lightweight which is suitable for use in energy, electronics industries.

[0010] The objective of this invention is to provide a comprehensive solution to the problem of industrial carbon dioxide (CO2) emissions, which are a major contributor to global warming and climate change. The system is designed to capture CO2 directly from emission sources, such as exhaust gases from industry, thereby reducing the amount of CO2 released into the atmosphere. This direct capture approach helps mitigate the environmental impact of industrial activities. Beyond emission reduction, the invention aims to add value to the captured CO2 by converting it into graphene, which is a high-value material known for its exceptional electrical conductivity, strength, and durability. This transformation allows CO2 to be utilized as a resource rather than treated as waste, creating new economic opportunities and generating income through its application in industries such as energy, electronics, and advanced materials. Another key objective is to reduce the cost and enhance the sustainability of the CO2 capture process. The system employs alkaline ceramic materials that are both durable and long-lasting. These ceramics can be produced from readily available sources, including biomass from industrial or agricultural waste, which contributes to lowering production costs and promoting environmental sustainability. Furthermore, the invention supports the achievement of Net Zero Carbon targets in the industrial sector. By providing an effective means of reducing CO2 emissions and maximizing the utilization of captured CO2, the system aligns with global efforts to reach carbon neutrality. In essence, this invention not only addresses the environmental challenge of CO2 emissions but also creates sustainable economic value through innovative material conversion.

[0011] Various purposes and features of the present invention will become clearer when considered together with the accompanying drawings and the best detailed description of the invention which will be described below.

[0012] Brief description of the drawings

[0013] The accompanying drawings, which are included herein to provide a further understanding of the present disclosure and are incorporated herein to constitute a part of the present specification. The accompanying drawings illustrate embodiments of the present disclosure and are used in conjunction with the following description to illustrate the concepts of the present disclosure.

[0014] Figure 1 illustrates flowchart and component of the reactor.

[0015] Figure 2 illustrates the process flow diagram of the graphene preparation from CO2 captured by the ceramic alkaline.

[0016] Figure 3 illustrates the images from Scanning Electron Microscope (SEM) of (a) carbon material which CO2 is captured by using activated carbon, and (b) graphene prepared by CO2 captured by using the ceramic alkaline.

[0017] Figure 4 illustrates the images from SEM and Energy-Dispersive X-ray Spectroscopy (EDS) of (a) carbon material which CO2 is captured by using activated carbon, and (b) graphene prepared by CO2 captured by using the ceramic alkaline. Figure 5 illustrates the images from Transmission Electron Microscope (TEM) of (a) graphene prepared by CO2 captured by using the ceramic alkaline, and (b) the analysis of the selected area electron diffraction (SAED).

[0018] Figure 6 illustrates the images from X-ray diffraction (XRD) pattern of (a) carbon material which CO2 is captured by using activated carbon and graphene prepared by CO2 captured by using the ceramic alkaline, and (b) the image of XRD pattern of prepared graphene material with high magnification.

[0019] Detailed description of the invention

[0020] This description of this invention will be made by illustrating the invention and referring to it by means of drawings and photographs to illustrate and clarify the description, and identical parts in these drawings will be represented by the same reference numbers. This is without any limitation and the scope of the invention will be in accordance with the appended claims.

[0021] This invention relates to a system that utilizes alkaline ceramic materials for the capture and utilization of carbon dioxide (CO2) in the industrial sector. The system is based on the design and development of high-pH ceramic materials capable of adsorbing and storing CO2 from sources such as factory exhaust gases. It demonstrates high efficiency in CO2 capture and enables the utilization of the captured CO2 as a resource in the production of high-quality graphene. The composition and operation of the system are illustrated in Figure 1, which presents the flow chart and components of the reactor [1], The alkaline ceramic media (ACM) used in this system is a specialized material for CO2 adsorption. It has a pH value greater than 11 and can maintain its alkalinity over extended periods. The developed ceramic media is composed of materials that resist the reaction with carbonic acid, which forms when CO2 reacts with water in the system. This resistance helps maintain the water’s pH above 11 and significantly enhances CO2 adsorption efficiency compared to conventional media. The system is capable of capturing CO2 from high-concentration sources [2], such as exhaust gases from industrial plants. CO2 is absorbed into alkaline water and reacts with the ceramic media, forming stable carbonate compounds. These compounds can be stored efficiently or further utilized in downstream processes, such as the conversion into graphene. The reaction is shown by the followings.

[0022] Carbon Capture via bicarbonate and carbonate

[0023] H2CO3 H++ HCO3- H++ CO32'

[0024] Carbonate Regeneration reaction

[0025] In addition, the use of activated carbon with a nanoplatelet structure and high surface area can enhance the efficiency of carbon dioxide (CO2) adsorption. This structural design allows the system to capture a greater number of CO2 molecules during the capture process. The effectiveness of activated carbon in this context is based on its intrinsic properties, including its exceptionally high surface area and porous structure, which enable efficient CO2 gas adsorption. The activated carbon employed in this system has been specifically developed to feature nanopores, tiny pores capable of capturing CO2 molecules even under high gas concentration conditions. The activated carbon is produced from biomass -derived materials such as wood chips, plant residues, or biochar. These materials, commonly considered waste in industrial and agricultural sectors, are repurposed to create activated carbon, thereby reducing biomass waste and enhancing the sustainability of the production process. During the CO2 absorption process, CO2 molecules are captured by the activated carbon through its nanoporous surface. When CO2 interacts with the surface, it forms compounds such as calcium bicarbonate (CafHCCh^), which contributes to improved adsorption efficiency. The nanoplatelet form of activated carbon used in this invention features thin sheet-like structures with complex porous networks, significantly increasing the CO2 absorption rate per unit volume. This system demonstrates high efficiency in CO2 capture due to the large surface area and fine pore structure of the activated carbon. Moreover, the use of biomass-derived materials in the production of activated carbon not only reduces waste but also lowers greenhouse gas emissions associated with the manufacturing process. The captured CO2 is subsequently utilized in the production of graphene or other high- value materials, enhancing the economic viability of the carbon capture system. This invention stands out for its use of activated carbon with a complex pore structure and high surface area, making it a highly effective solution for reducing greenhouse gas emissions. Additionally, the captured CO2 can be efficiently utilized in industrial applications, particularly in graphene production [3], having outstanding structural and chemical properties . The conversion of CO2 into graphene occurs under controlled processing conditions, as illustrated in the accompanying figures. Figure 2 illustrates the flow diagram of the graphene material preparation process. The carbon material, captured using activated carbon, undergoes a purification step to remove organic matter and impurities. This is achieved through a leaching process combined with selective centrifugation. After purification, the material is dried and characterized using various analytical techniques, including scanning electron microscopy (SEM), Energy-Dispersive X-ray Spectroscopy (EDS), transmission electron microscopy (TEM), and X-ray diffraction (XRD). When purified, the carbon material is dispersed in a medium for separation and restacking via a high-frequency sonotrode horn reactor based on the characteristics of eddy currents to generate a multi-step batch reaction. Although such reactors are commonly used in biology, physics, and chemistry for mixing, extraction, crystallization, separation, and cultivation, there have been no prior reports on their use in the preparation of graphene. The fluid dynamics within the reactor are complex and involve the formation of a double vortex, one flowing in the direction of the shaft’s normal rotation and the other in the opposite direction. This unique flow pattern is referred to as a Taylor Vortex. The Taylor Vortex induces shear stress on the carbon material byproduct introduced into the reactor. This shear stress acts in opposite directions along the sides of the carbon particles, facilitating the exfoliation of individual carbon layers. The reactor’s- controlled rotation enables the peeling of carbon into thin sheets, resulting in the formation of graphene. The graphene produced through this process exhibits properties suitable for a wide range of applications, including nano-scale electrical and electronic devices, nanosensors, optoelectronic components, and high-performance composite materials. Following the exfoliation process, the graphene material is separated from the medium, dried, and subjected to particle size reduction through grinding. This results in the final graphene product, derived from carbon dioxide captured using alkaline ceramics and activated carbon.

[0026] Figure 3 presents the results of scanning electron microscopy (SEM) characterization of two materials: (a) carbon material which CO2 is captured by using activated carbon, and (b) graphene prepared by CO2 captured by using the ceramic alkaline. The SEM analysis shows distinct morphological differences between the two samples. The carbon materials captured using activated carbon exhibit a morphology characterized by clustered structures, resembling graphite-like formations. These clusters contain residual organic matter and impurities. Whereas the graphene materials show a morphology consisting of thin sheets that are stacked in layers. These sheets are uniformly distributed and free from organic substances or impurities.

[0027] Figure 4 illustrates the characterization of material using scanning electron microscopy (SEM) and Energy-Dispersive X-ray Spectroscopy (EDS) for two samples: (a) carbon material which CO2 is captured by using activated carbon, and (b) graphene prepared by CO2 captured by using the ceramic alkaline. The analysis shows that the carbon material captured using activated carbon exhibited a surface morphology composed of 68.9% carbon, and 31.1% of various organic compounds and impurities, including oxygen, calcium, magnesium, phosphorus, potassium, silicon, and aluminium, indicating the presence of residual biomass-derived components. Whereas the graphene material prepared from carbon dioxide captured with alkaline ceramics showed a significantly higher carbon content of 94.1%, with only 5.9% of residual organic compounds. This result demonstrates the high purity and quality of the graphene produced through the described process.

[0028] Figure 5 shows the results of transmission electron microscopy (TEM) characterization of (a) graphene prepared by CO2 captured by using the ceramic alkaline, and (b) the analysis of the selected area electron diffraction (SAED). The TEM images show wrinkled structure, which is attributed to the thermochemical processing and the presence of oxygen -containing functional groups within the graphene layers. The electron diffraction pattern displayed two distinct diffraction rings corresponding to the 002 and 100 crystal planes. The presence of well-defined spots along these rings indicates a well-ordered hexagonal lattice structure, confirming the crystalline nature of the prepared graphene material.

[0029] Figure 6 presents the results of X-ray diffraction (XRD) pattern of (a) carbon material which CO2 is captured by using activated carbon and graphene prepared by CO2 captured by using the ceramic alkaline, and (b) the image of XRD pattern of prepared graphene material with high magnification. The XRD analysis of the carbon material shows diffraction peaks at theta angles of 26.38° and 54.54°, corresponding to the 002 and 004 crystal planes, which is the characteristic of graphite structures. The d-spacing of the 002 crystal plane was measured at 0.3375 nm, which closely matches the theoretical value of 0.3340 nm for graphite. Based on this data, the degree of graphitization was calculated to be approximately 75.58%, whereas the graphene material prepared from carbon dioxide captured with alkaline ceramics exhibited broader and less intense diffraction peaks at the same crystal planes (002 and 004). The d- spacing of the 002 plane was found to be 0.3856 nm, indicating a more disordered structure and clear separation of graphene layers, which is typical of exfoliated graphene. The graphene storage and application [4], the graphene produced through this process can be safely stored and utilized in various industrial applications, including energy systems, electronics, and the manufacturing of high-durability materials. The utilization of CO2 in this invention enables the production of high-quality graphene, which can be applied in sectors such as energy generation, electronic device fabrication, and structural materials requiring enhanced mechanical properties. The working principle of the system involves the adsorption of CO2 into alkaline water, where it reacts with the alkaline ceramic media (ACM). These ceramics are resistant to carbonic acid reactions and help maintain the water’s high pH level during CO2 absorption. The resulting carbonate compounds can be separated and either stored or processed into other valuable materials, such as graphene. The graphene obtained from this process possesses properties suitable for a wide range of industrial applications and contributes to the economic value of carbon capture systems.

[0030] This invention offers several key advantages that make it a promising solution for industrial carbon dioxide (CO2) capture and utilization. First, it demonstrates high efficiency in CO2 adsorption. The use of alkaline ceramic materials with a high pH value significantly enhances the adsorption process, resulting in stable and long-term carbon sequestration. This ensures that CO2 is effectively captured and retained within the system. Second, the invention creates added value from captured CO2 by converting it into graphene which is a high-value material with wide-ranging industrial applications. This transformation makes the process not only a method for reducing greenhouse gas emissions but also a profitable approach for industries seeking sustainable innovation. Third, the system promotes sustainability and cost-effectiveness. By utilizing biomass-based materials in the production of alkaline ceramics, the invention reduces production costs and minimizes biomass waste. This environmentally friendly approach supports long-term sustainability and aligns with circular economy principles. Finally, the invention supports the reduction of greenhouse gas emissions and contributes to the achievement of carbon neutrality (Net Zero) goals in the industrial sector.

[0031] By providing an efficient and economically viable method for CO2 capture and utilization, the system addresses both environmental and industrial needs in a comprehensive and forwardlooking manner.

[0032] Although the present invention has been described in detailed description by means of the attached drawings, it is understood that modifications or alterations by a person who skilled in the art and science, within the scope and purpose of the invention, can be made. The scope of the present invention shall be in accordance with the embodiment of the invention as stated in the appended claims, including aspects of the invention, although it is not specifically stated in the claims, have a utility and produce results similar to those of the invention as stated in the claims. Best mode for carrying out the invention

[0033] Best mode or preferred embodiment of the invention is as provided in the description of the invention.

Claims

Claims1. A system for carbon dioxide capture and utilization in industry, comprising an alkaline ceramic media (ACM) with high alkalinity, which the media is configured or configurable to adsorb and capture CO2 from carbon source, exhaust gas from manufacturing process in the industry, which maintain the suitable alkalinity for efficient and stable CO2 adsorption during use.

2. The system as claimed in claim 1, further comprising nanoplatelet activated carbon produced from biomass, having a high surface area to enhance CO2 adsorption efficiency, resistance to environments with high CO2 concentrations, and continuous reusability within the carbon capture system.

3. A process for converting captured carbon dioxide in the system as claimed in claims 1 or 2 to graphene, the process comprising the separation of carbon, and restacking the graphene using shearing force from specific reactor to obtain the graphene with high purity, durability, and electrical conductivity.

4. The system as claimed in claims 1 or 2, using the alkaline ceramic media and activated carbon from biomass having sustainable CO2 adsorption, the media and activated carbon are resistant to chemical reactions and harsh environmental condition in the industry, and can reduce the biomass waste and use the locally available source.

5. The process as claimed in claim 3, comprising the steps of leaching, drying, separating by centrifugation, dispersing in medium, and grinding, to obtain the high quality of graphene which is suitable for the energy industry, electronic industry, and industry to produce material with high strength.

6. The system and process as claimed in any one of the preceding claims, which can use the captured CO2 for process in producing high value carbon materials, wherein the process can reduce the CO2 emission in the industry, while also making the economic benefit from the use of CO2 in value-added forms.

7. A use of graphene from the process as claimed in claim 3 or 5, in material production, with high electrical conductivity, durable, and chemically and physically efficient, that is energy storage device, high strength structure material, and nanosensors in the industry

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