Method and equipment for extracting carbon materials from plastics

Patent metadata

Field	Value
Publication number	US-2020262708-A1
Application number	US-201816491108-A
Country	US
Kind code	A1
Filing date	May 22, 2018
Priority date	May 22, 2018
Publication date	Aug 20, 2020
Grant date	—

Abstract

The invention provides a method and equipment for extracting carbon materials from plastics. Particularly, the method produces nanostructured carbon materials by heating of at least one salt (e.g., NaCl) and at least one plastic material (e.g.polyethylene terephthalate) to a temperature greater than the melting point of the said salt, in which molten state of the said salt protects the carbonaceous material from oxidation. Moreover, molten salt promotes the graphitization of carbon materials. The product is in the form of graphenenano-flakes with high conductivity and high surface area. This method provides a simple, economical and efficient approach for producing conductive carbon materials. It also has a significant positive impact on the environment through the transformation of virtually non-degradable plastic wastes into high-value conductive carbon materials.

First claim

1 . A method for extracting carbon materials from plastics, wherein nanostructured carbon materials are produced by heating a mixture consisting of at least one plastic and at least one metal halide salt to a heating temperature in the range defined as: the melting point of the salt≤heating temperature≤the boiling point of the salt+50° C.

2 . The method for extracting carbon materials from plastics according to claim 1 , wherein the salt is a hydrated metal halide salt.

3 . The method for extracting carbon materials from plastics according to claim 1 , wherein the heating temperature is above the melting point of the metal halide salts, and less than the boiling temperature of the salts, by which a mixture of nanostructured carbon materials and salts is produced; after the mixture is cooled down, the salts are dissolved by water followed by filtration to retrieve the nanostructured carbon materials and the solution of the water and the salts; the nanostructured carbon materials are collected after drying and the salts are recycled from the solution.

4 . The method for extracting carbon materials from plastics according to claim 1 , wherein the conductivity of the synthesized nanostructured carbon material is greater than 1000 S m −1 or the value of Raman I D /I G is less than 0.5.

5 . The method for extracting carbon materials from plastics according to claim 1 , wherein the salt is one metal halide salt or a mixture of metal halide salts selected from the group consisting of LiCl, NaCl, KCl, MgCl 2 , CaCl 2 , NaF and ZnCl 2 ; the salt can be a hydrated metal halide salt or a mixture of more than one hydrated metal halide salt selected from the group consisting of hydrated forms of LiCl, NaCl, KCl, MgCl 2 , CaCl 2 , NaF and ZnCl 2 .

6 . The method for extracting carbon materials from plastics according to claim 1 , wherein the plastics include at least one of polyethylene, polypropylene, polyethylene terephthalate, polystyrene, polyvinyl chloride, polylactide, polycarbonate, acrylic acid, nylon and ABS resin or synthetic rubbers.

7 . The method for extracting carbon materials from plastics according to claim 1 , wherein the heating is carried out in air, inert gas atmosphere, nitrogen atmosphere or vacuum conditions; when the heating atmosphere is an inert gas or nitrogen, the atmosphere contains H 2 above 0.1% volume fraction.

8 . The method for extracting carbon materials from plastics according to claim 1 , wherein the nanostructured carbon produced has one or more of the following properties: surface area of greater than 500 m 2 g −1 ; capacitance of greater than 70 F g −1 ; having a graphitic structure; having a symmetrical Raman 2D band; containing graphene nanolayers with the number of layers of less than 20 layers, with a flake thickness of less than 10 nm.

9 . The method for extracting carbon materials from plastics according to claim 1 , wherein the metal halide salt is NaCl and the plastic is polyethylene terephthalate (PET), and the heating temperature is above 1100° C.

10 . An equipment by which the method for extracting carbon materials from plastics according to claim 1 is implemented, wherein the equipment includes a tunnel furnace with a moving load bracket; the moving load bracket is made of refractory materials or covered with alumina panels fitted on a metallic rail; the upper part of the tunnel furnace is provided with heating elements installed on refractory materials; the heating element can be gas or electricity powdered, providing temperature needed for the reaction; the upper part of the tunnel furnace is provided with a hole connected to a gas extraction system for collecting the gaseous substances released during the reaction process; a refractory container is placed on the moving load bracket, in which the salt and the plastic are loaded, and moves with the moving load bracket during the reaction from one end of the tunnel furnace to the other end, within which the temperature increases and then decreases, and finally the refractory container comes out of the tunnel furnace; a post-treatment and the recycling device is used to treat the reaction products obtained from the refractory container by water after the heating process, by which the salt is dissolved, followed by filtering the suspended nanostructured carbon materials, and dry out the final product; the waste heat from the tunnel furnace is used to evaporate the excess water of the filtration liquid to recover the reactant salt for reuse.

11 . The method for extracting carbon materials from plastics according to claim 2 , wherein the heating temperature is above the melting point of the metal halide salts, and less than the boiling temperature of the salts, by which a mixture of nanostructured carbon materials and salts is produced; after the mixture is cooled down, the salts are dissolved by water followed by filtration to retrieve the nanostructured carbon materials and the solution of the water and the salts; the nanostructured carbon materials are collected after drying and the salts are recycled from the solution.

12 . The method for extracting carbon materials from plastics according to claim 2 , wherein the conductivity of the synthesized nanostructured carbon material is greater than 1000 S m −1 or the value of Raman I D /I G is less than 0.5.

13 . The method for extracting carbon materials from plastics according to claim 2 , wherein the salt is one metal halide salt or a mixture of metal halide salts selected from the group consisting of LiCl, NaCl, KCl, MgCl 2 , CaCl 2 , NaF and ZnCl 2 ; the salt can be a hydrated metal halide salt or a mixture of more than one hydrated metal halide salt selected from the group consisting of hydrated forms of LiCl, NaCl, KCl, MgCl 2 , CaCl 2 , NaF and ZnCl 2 .

14 . The method for extracting carbon materials from plastics according to claim 2 , wherein the plastics include at least one of polyethylene, polypropylene, polyethylene terephthalate, polystyrene, polyvinyl chloride, polylactide, polycarbonate, acrylic acid, nylon and ABS resin or synthetic rubbers.

15 . The method for extracting carbon materials from plastics according to claim 2 , wherein the heating is carried out in air, inert gas atmosphere, nitrogen atmosphere or vacuum conditions; when the heating atmosphere is an inert gas or nitrogen, the atmosphere contains H 2 above 0.1% volume fraction.

16 . The method for extracting carbon materials from plastics according to claim 2 , wherein the nanostructured carbon produced has one or more of the following properties: surface area of greater than 500 m 2 g −1 ; capacitance of greater than 70 F g −1 ; having a graphitic structure; having a symmetrical Raman 2D band; containing graphene nanolayers with the number of layers of less than 20 layers, with a flake thickness of less than 10 nm.

17 . The method for extracting carbon materials from plastics according to claim 2 , wherein the metal halide salt is NaCl and the plastic is polyethylene terephthalate (PET), and the heating temperature is above 1100° C.

Assignees

• Univ Northeastern

Inventors

• Kamali Ali Reza

Classifications

• B09B3/80

  involving an extraction step · CPC title

• B09B3/40

  involving thermal treatment, e.g. evaporation (processes using mineral binders involving a melting or softening step B09B3/29; involving radiation B09B3/50) · CPC title

• F27B9/20

  the charge moving in a substantially straight path · CPC title

• B29L2031/7158

  Bottles · CPC title

• C01P2002/82

  by IR- or Raman-data · CPC title