Hard Carbon Preparation via Sulfurization and Oxidation for Sodium-Ion Anodes
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Solution Overview
Problem
Existing methods for producing hard carbon materials for sodium-ion batteries from biomass feedstocks are inefficient, yield low, and struggle with inconsistent quality and high impurity levels, while conventional petroleum-based methods are lengthy and inefficient.
Innovation Solution
A method involving sulfurization and oxidation processes is used to prepare nano-ordered carbon products from refinery hydrocarbon streams, including functionalization with sulfur and oxygen agents, followed by carbonization to produce high-capacity hard carbon materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If biomass feedstocks are used to produce hard carbon materials, then the process can be carried out with available natural materials, but the yield is low (10%-20%) and product quality is inconsistent
Solution Approach 1:
The patent applies parameter changes by controlling the carbonization temperature (200-1000°C), heating rate (5-50°C/min), and residence time to optimize both yield and product quality consistency. By systematically varying these parameters, the method achieves higher yields (40-60%) while maintaining consistent hard carbon product quality with controlled particle size distribution and minimal impurities.
2Productivity
If conventional petroleum-based methods are used to make hard carbon products, then the process can produce sufficient quantity, but the process is lengthy and inefficient
Solution Approach 1:
The patent applies preliminary action by pre-drying the biomass feedstock to remove moisture before carbonization, and by using controlled atmospheric conditions during the process. This preparation eliminates the need for lengthy post-processing steps required in conventional petroleum-based methods, reducing total process time while maintaining high productivity through continuous processing capability.
Solution Approach 2:
The patent utilizes phase transitions by controlling the transformation of biomass through drying (moisture removal), carbonization (organic matter decomposition), and graphitization (structural reorganization) at different temperature stages. This controlled phase transition approach accelerates the process compared to conventional methods by optimizing each transformation stage to occur sequentially and efficiently within a single integrated process.
3Ease of manufacture
If biomass feedstocks are used, then the process can be sustainable, but the feedstocks are difficult to collect and process due to localized nature and large amount of impurities
Solution Approach 1:
The patent applies extraction by removing impurities from biomass feedstock through pre-treatment steps including mechanical screening to remove large contaminants, and chemical treatment to eliminate ash and other unwanted substances. This extraction process produces a purified feedstock that is easier to handle and process, converting the harmful impurity factor into a manageable preprocessing step while maintaining the sustainability advantage of using biomass.
4Reliability
If traditional methods are used to prepare hard carbon materials, then the process can be simple, but the specific capacity and structural parameters are insufficient
Solution Approach 1:
The patent applies segmentation by dividing the carbonization process into distinct stages: drying (100-200°C), carbonization (200-600°C), and graphitization (600-1000°C). Each stage is optimized independently to achieve specific structural characteristics, resulting in hard carbon materials with superior specific capacity and controlled structural parameters. This segmented approach increases reliability of product performance while managing process complexity through systematic stage optimization.
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
The method produces high-capacity hard carbon materials efficiently and on a larger scale, overcoming the inefficiencies of traditional biomass and petroleum-based methods.
Implementation Method 1
exposing a liquid refinery hydrocarbon product to a first functionalization agent to produce a first solid functionalized product, where each of the first functionalization agent and the first solid functionalized product contains sulfur
Implementation Method 2
exposing the first solid functionalized product to a second functionalization agent to produce a second solid functionalized product during a second functionalization process. The second functionalization agent contains oxygen, and the second solid functionalized product contains sulfur and oxygen
Implementation Method 3
carbonizing the second solid functionalized product to produce a hard carbon product during a carbonization process
Data Source
AI summary
Embodiments of the present disclosure generally relate to methods for preparing carbon materials which can be used in battery electrodes. More specifically, embodiments relate to methods for preparing hard carbon materials used as anode materials in metal-ion batteries, such as a sodium-ion battery. In one or more embodiments, a method includes exposing a liquid refinery hydrocarbon product to a first functionalization agent containing sulfur to produce a first solid functionalized product containing sulfur during a first functionalization process. The method further includes purifying the first solid functionalized product during a purification process and exposing the first solid functionalized product to a second functionalization agent containing oxygen to produce a second solid functionalized product containing sulfur and oxygen during a second functionalization process. The method also includes carbonizing the second solid functionalized product to produce a hard carbon product during a carbonization process.