Nano-Ordered Carbon from Refinery Streams for High-Yield Battery Anodes
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Solution Overview
Problem
Conventional methods for producing hard carbon anode materials for sodium-ion batteries from biomass feedstocks are inefficient, yield low, and difficult to control, while petroleum-based methods are lengthy and inefficient, lacking in high specific capacity and structural parameters.
Innovation Solution
A method involving multiple functionalization and carbonization processes using oxygen, sulfur, phosphorous, or nitrogen-based agents to convert refinery hydrocarbon streams into solid nano-ordered carbon products, optimizing structural parameters and yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional methods use biomass feedstocks to produce hard carbon anode materials, then the process is simpler, but the yield is low (10%-20%) and quality control is difficult
Solution Approach 1:
The patent changes the feedstock parameter from biomass to petroleum-based feedstocks (VAC, HCC, FCC slurry oils), and modifies process parameters including multi-step functionalization with different agents (nitric acid, sulfuric acid, hydrogen peroxide), controlled temperature ranges (200-400°C for functionalization, 800-1500°C for carbonization), and staged oxidation conditions to achieve high yield (50-70%) and consistent quality
Solution Approach 2:
The patent segments the carbonization process into distinct stages: initial functionalization to introduce oxygen-containing groups, purification to remove impurities, secondary functionalization to further modify structure, and final carbonization. This segmented approach allows precise control over each step to maximize yield and product quality
2Quantity of substance
If petroleum-based methods are used to make hard carbon products, then abundant feedstock is available, but the process is lengthy and inefficient
Solution Approach 1:
The patent applies preliminary functionalization treatments to the petroleum feedstock before carbonization, introducing oxygen-containing functional groups that facilitate subsequent processing and improve product quality. This preliminary action prepares the feedstock in advance, making the overall process more efficient despite multiple steps
Solution Approach 2:
The patent implements continuous processing where functionalization, purification, and carbonization steps are sequentially connected without interruption. The multi-step functionalization process continuously modifies the feedstock structure, and the purified intermediate is immediately carbonized, maintaining continuous useful action throughout to improve overall efficiency
3Device complexity
If biomass feedstocks are used, then the process requires fewer steps, but the product lacks high specific capacity and consistent structural parameters
Solution Approach 1:
The patent precisely controls critical parameters including functionalization temperature (200-400°C), carbonization temperature (800-1500°C), treatment time, and chemical agent concentrations. These parameter changes enable consistent production of hard carbon with specific capacity >300 mAh/g and controlled d-spacing (0.34-0.36 nm), achieving manufacturing precision that biomass methods cannot match
Solution Approach 2:
The patent incorporates quality control feedback mechanisms where intermediate products are analyzed after each processing step (functionalization, purification, carbonization). Based on analysis results, process parameters are adjusted to ensure consistent structural parameters and high specific capacity, achieving precise manufacturing control
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-specific capacity nano-ordered carbon materials suitable for sodium-ion batteries, offering improved efficiency and yield compared to traditional methods.
Implementation Method 1
exposing a liquid refinery hydrocarbon product to a first functionalization agent to produce a first solid functionalized product during a first functionalization process, where the first functionalization agent contains at least one element selected from oxygen, sulfur, phosphorous, nitrogen
Implementation Method 2
carbonizing the second solid functionalized product to produce a solid nano-ordered 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 nano-ordered carbon products used as anode materials in metal-ion batteries, such as a sodium-ion battery. In one or more embodiments, a method for preparing a nano-ordered carbon is provided and includes exposing a liquid refinery hydrocarbon product to a first functionalization agent to produce a first solid functionalized product during a first functionalization process and purifying the first solid functionalized product during a purification process. The method also includes exposing the first solid functionalized product to a second functionalization agent to produce a second solid functionalized product during a second functionalization process and carbonizing the second solid functionalized product to produce a solid nano-ordered carbon product during a carbonization process.