Coal-to-Graphene Conversion via Oxidation and Reduction Stages
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Solution Overview
Problem
There is a need to develop processes that convert coal into high-value, high-performance carbon-based products such as graphene and other advanced carbon materials efficiently and economically, as existing methods for deriving fuels and other products from coal have not been economically feasible at large scales.
Innovation Solution
A method involving thermal processing of coal at temperatures above 300°F, followed by oxidization, centrifugation, and reduction to form reduced graphene oxide, which includes steps like mixing coal with acids or potassium permanganate, sonicating, and hydrothermal treatment in a PARR® reactor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If coal is thermally processed and chemically converted to produce advanced carbon materials like graphene, then high-value products are obtained, but the process complexity and cost increase significantly
Solution Approach 1:
The patent divides the coal conversion process into distinct sequential stages: thermal processing at 300°F to activate coal, oxidation with KMnO4 and acids to form graphene oxide, centrifugation to separate particles, and reduction to produce reduced graphene oxide. Each stage isolates specific transformations, making the complex overall process more manageable and controllable while achieving 10-20% yield
Solution Approach 2:
The patent uses graphene oxide as an intermediary substance formed during oxidation of thermally processed coal. This intermediate compound serves as a bridge between the raw coal and the final reduced graphene oxide product, allowing for controlled transformation and separation through centrifugation before final reduction, thereby simplifying the overall conversion pathway
2Use of energy by moving object
If traditional coal incineration is used for heat and power generation, then energy production is achieved, but adverse environmental and economic effects occur
Solution Approach 1:
The patent converts coal, traditionally burned for energy production that causes environmental harm, into high-value advanced carbon materials through thermal processing and chemical transformation. This transforms coal from a pollutant-generating fuel into a precursor for graphene and other advanced materials, eliminating incineration-related environmental damage while creating economic value
Solution Approach 2:
The patent fundamentally changes the processing parameters of coal from high-temperature incineration (combustion) to controlled thermal processing at 300°F followed by chemical oxidation and reduction. This parameter change transforms the chemical pathways, preventing complete combustion and environmental pollution while producing desired advanced carbon materials
3Manufacturing precision
If coal is processed to retain impurity atoms like boron, nitrogen, and silicon, then dopant atoms are incorporated into graphene, but purification complexity increases
Solution Approach 1:
The patent performs preliminary thermal processing of coal at 300°F before oxidation to activate the coal structure and prepare it for subsequent chemical reactions. This preliminary action ensures that impurity atoms like boron, nitrogen, and silicon are positioned and activated in the coal matrix before oxidation, facilitating their controlled incorporation into the resulting graphene structure during the oxidation-reduction process
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 achieves a yield of reduced graphene oxide between 10-20% from coal, retaining impurity atoms like boron, nitrogen, and silicon, and produces synthetic graphene with predetermined dopant atoms and point defects.
Implementation Method 1
thermally processing coal at a temperature of at least about 300° F.
Implementation Method 2
oxidizing the coal to form a coal oxide
Implementation Method 3
centrifuging the coal oxide, collecting precipitate from the coal oxide after centrifuging
Implementation Method 4
reducing the graphene oxide to form reduced graphene oxide
Implementation Method 5
sonicating
Implementation Method 6
hydrothermally treating the graphene oxide in a PARR® reactor
Data Source
AI summary
A method of preparing graphene from coal can include thermally processing raw coal and, after the coal has been at least partially cooled from thermal processing, forming reduced graphene oxide from the coal.