Graphene Synthesis from Asphaltenes via Carboxylation
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Solution Overview
Problem
Current methods for producing graphene are hindered by challenges such as high costs, lack of scalability, and inconsistency in properties like size, number of layers, and purity, which hinder its commercialization and real-life applications, while asphaltenes, despite their potential, are underutilized due to high maintenance costs and environmental issues.
Innovation Solution
A method involving the contact of an asphaltene composition with CO2 to produce a carboxylated asphaltene derivative, followed by interaction with modifying agents or reducing agents to synthesize pure and precise graphene, with subsequent purification to isolate a graphene material, controlling its structural and chemical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional graphene production methods (CVD, exfoliation, arc discharge) are used, then graphene can be produced, but the production cost is high and scalability is limited
Solution Approach 1:
The patent uses asphaltenes, a low-cost waste byproduct from petroleum refining, as the starting material for graphene synthesis. This replaces expensive conventional starting materials and enables cost-effective large-scale production. The asphaltene feedstock is abundant, inexpensive, and readily available from existing industrial processes.
Solution Approach 2:
The patent employs controlled chemical parameters including temperature (60-150°C for carboxylation, higher temperatures for reduction), pH control during modification, and staged addition of reagents (KMnO4, NaOH, ascorbic acid) to optimize the conversion of asphaltenes to graphene. These parameter controls enable consistent product quality at scale.
2Manufacturing precision
If conventional graphene production methods are used, then graphene can be produced, but consistency in properties (size, number of layers, purity) is poor
Solution Approach 1:
The patent performs preliminary carboxylation of asphaltenes with CO2 before the main reduction step to graphene. This pre-treatment functionalizes the asphaltene structure in a controlled manner, creating uniform starting material for subsequent reduction. The carboxylation step (60-150°C, extended time) ensures consistent functional group distribution that translates to consistent final graphene properties.
Solution Approach 2:
The patent employs systematic monitoring and control of reaction parameters including pH adjustments during modification, temperature control during reduction, and characterization feedback (Raman spectroscopy, XRD, TEM) to optimize and maintain consistent graphene product properties. This feedback loop enables reproducible manufacturing at scale.
3Productivity
If asphaltenes are removed from crude oil, then crude oil processing can proceed, but asphaltenes cause high maintenance costs and environmental issues
Solution Approach 1:
The patent transforms asphaltenes, traditionally viewed as harmful contaminants causing deposition and maintenance issues in crude oil processing, into a valuable precursor for graphene production. The same asphaltene molecules that cause problems are converted into high-value carbon nanomaterials, turning a waste stream into a resource.
Solution Approach 2:
Instead of discarding asphaltenes as waste material requiring costly removal and disposal, the patent recovers and utilizes them as feedstock for graphene synthesis. The process captures asphaltenes from crude oil processing and converts them into valuable graphene products, creating a circular economy approach to asphaltene management.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enables the cost-effective and scalable production of high-quality graphene with controlled properties, addressing the limitations of existing graphene production techniques and providing a value-added use for asphaltenes, while also considering environmental sustainability.
Implementation Method 1
contacting an asphaltene composition with CO2 wherein a carboxylated asphaltene derivative is produced
Implementation Method 2
contacting the carboxylated asphaltene derivative with one or more modifying agents or reducing agents wherein a graphene composition is produced
Implementation Method 3
purifying the graphene composition to isolate a pure graphene material
Data Source
AI summary
The present invention discloses a method for synthesizing graphene by eliminating one or more functional groups from a 2D carbon allotropes of graphene having a lattice structure selected from an orthorhombic system, a monoclinic system, and a triclinic system. The present invention discloses a method for synthesizing graphene by eliminating one or more functional groups from a network of one or more 2D nanostructures having a lattice structure formed by an asymmetric structural unit (CxHyF) where x=6, or 7, 3<=y<=9 and F is one or more functional groups.