Methods and apparatuses for production of carbon, carbide electrodes, and carbon compositions

Patent metadata

Field	Value
Publication number	US-9909222-B2
Application number	US-201514886319-A
Country	US
Kind code	B2
Filing date	Oct 19, 2015
Priority date	Oct 21, 2014
Publication date	Mar 6, 2018
Grant date	Mar 6, 2018

Abstract

Method comprising providing at least one solid carbide chemical compound and reducing a metal cation with use of the solid carbide chemical compound. A method comprising producing elemental carbon material from the oxidation of carbide in at least one carbide chemical compound (e.g., calcium carbide) in at least one anode of an electrochemical cell apparatus, such as a galvanic cell apparatus. The cathode can be a variety of metals such as zinc or tin. The reaction can be carried out at room temperature and normal pressure. An external voltage also can be applied, and different forms of carbon can be produced depending on the reactants used and voltage applied. For carrying out the method, an apparatus comprising at least one galvanic cell comprising: at least one anode comprising at least one carbide chemical compound, and at least one cathode. For carrying out the method and constructing the apparatus, an electrode structure comprising at least one carbide chemical compound, wherein the carbide chemical compound is a salt-like carbide; and at least one electronically conductive element different from the carbide. Carbon compositions of various forms are also prepared by the methods and apparatus and with use of the electrode structure. Large pieces of pure carbon can be produced. Post-reaction processing of the carbon can be carried out such as exfoliation.

First claim

What is claimed:

1. A method comprising:
producing elemental carbon material from the oxidation of carbide in at least one carbide chemical compound in at least one anode of an electrochemical cell apparatus, wherein the electrochemical cell apparatus is a galvanic cell apparatus, and wherein the elemental carbon material is produced at a reaction pressure of about 0.1 torr to about 5 atmospheres.

2. The method of claim 1 , wherein the carbide chemical compound is a salt-like carbide or an intermediate transition metal carbide.

3. The method of claim 1 , wherein the carbide chemical compound is a salt-like carbide.

4. The method of claim 1 , wherein the carbide chemical compound is a methanide, an acetylide, or a sesquicarbide.

5. The method of claim 1 , wherein the carbide chemical compound is calcium carbide, aluminum carbide, sodium carbide, magnesium carbide, lithium carbide, beryllium carbide, iron carbide, copper carbide, and chromium carbide.

6. The method of claim 1 , wherein the carbide chemical compound is calcium carbide or aluminum carbide.

7. The method of claim 1 , wherein the carbide chemical compound has sufficient electronic conductivity to function as an anode.

8. The method of claim 1 , wherein the carbide chemical compound has an electronic conductivity of at least 10 −8 S/cm.

9. The method of claim 1 , wherein the electrochemical cell apparatus further comprises at least one cathode.

10. The method of claim 1 , wherein the electrochemical cell apparatus further comprises at least one cathode which is a metal cathode.

11. The method of claim 1 , wherein the electrochemical cell apparatus further comprises at least one metal cathode, wherein the cathode is a zinc, tin, iron, copper, or silver cathode.

12. The method of claim 1 , wherein the electrochemical cell apparatus further comprises at least one metal cathode, wherein the cathode is a zinc or tin cathode.

13. The method of claim 1 , wherein the electrochemical cell apparatus anode is contacted with at least one first solution comprising at least one solvent and at least one salt and the electrochemical cell apparatus further comprises at least one cathode which is also contacted with at least one solution comprising at least one solvent and at least one salt.

14. The method of claim 1 , wherein the electrochemical cell apparatus further comprises at least one salt bridge.

15. The method of claim 1 , wherein the electrochemical cell apparatus further comprises at least one ion exchange membrane.

16. The method of claim 1 , wherein a reaction temperature for producing the elemental carbon material is about 10° C. to about 90° C.

17. The method of claim 1 , wherein a reaction temperature for producing the elemental carbon material is about 15° C. to about 50° C.

18. The method of claim 1 , wherein a reaction temperature for producing the elemental carbon material is about room temperature.

19. The method of claim 1 , wherein the reaction pressure for producing the elemental carbon material is about 0.9 atmosphere to about 1.1 atmosphere.

20. The method of claim 1 , wherein the reaction pressure for producing the elemental carbon material is about 720 torr to about 800 torr.

21. The method of claim 1 , wherein the elemental carbon material is produced at about 15° C. to about 50° C. and about 720 torr to about 800 torr.

22. The method of claim 1 , wherein the production of elemental carbon material is carried out without use of an external voltage source.

23. The method of claim 1 , wherein the electrochemical cell apparatus comprises an external voltage source to regulate the oxidation reaction.

24. The method of claim 1 , wherein the production of elemental carbon material is carried out with use of an external voltage source to regulate the oxidation reaction.

25. The method of claim 1 , wherein the production of carbon is carried out with use of an external voltage source to regulate the oxidation reaction, and an external voltage is used at a particular voltage to enhance production of one elemental carbon material product over other different elemental carbon material products.

26. The method of claim 1 , wherein the elemental carbon material is more than 50% sp2 carbon.

27. The method of claim 1 , wherein the elemental carbon material is more than 50% sp3 carbon.

28. The method of claim 1 , wherein the elemental carbon material is more than 90% carbon.

29. The method of claim 1 , wherein the elemental carbon material comprises two-dimensional plate-like structures.

30. The method of claim 1 , wherein the elemental carbon material comprises two-dimensional plate-like structures stacked on top of one another.

31. The method of claim 1 , wherein the elemental carbon material comprises at least some three-dimensional structures.

32. The method of claim 1 , wherein the elemental carbon material comprises at least one piece which has a lateral dimension of at least one mm.

33. The method of claim 1 , wherein the elemental carbon material is subjected to at least one purification step.

34. The method of claim 1 , wherein the elemental carbon material is treated with acid and water.

35. The method of claim 1 , wherein the elemental carbon material is subjected to at least one step which produces particles of the elemental carbon material.

36. The method of claim 1 , wherein the elemental carbon material is subjected to at least one exfoliation step to produce graphene.

37. The method of claim 1 , wherein the galvanic cell apparatus produces electrical power to power at least one load which is another electrochemical cell.

38. The method of claim 1 , wherein the carbide chemical compound is calcium carbide or aluminum carbide, wherein the galvanic cell apparatus anode is contacted with a solution comprising at least one organic solvent and at least one dissolved salt, and the galvanic cell apparatus cathode is also contacted with a solution comprising at least one organic solvent and at least one dissolved salt, and wherein the elemental carbon material is produced at about 15° C. to about 50° C. and about 720 torr to about 800 torr.

39. The method of claim 1 , wherein the carbide chemical compound is in the form of individual pieces or particles.

40. The method of claim 1 , wherein the carbide chemical compound is in the form of individual pieces or particles having a size of less than one cm.

41. The method of claim 1 , wherein the carbide chemical compound contacts at least one electrically conductive material.

42. The method of claim 1 , wherein the carbide chemical compound is held in an electrically conductive container.

43. The method of claim 1 , wherein the apparatus further comprises at least one solution comprising at least one solvent and at least one dissolved salt, and the solution is free of dissolved carbide chemical compound.

44. An electrochemical cell apparatus for carrying out the method of claim 1 .

45. The method of claim 1 , wherein the anode is an anode electrode structure comprising the at least one carbide chemical compound, where

Assignees

• Univ West Virginia

Inventors

• Stiller Alfred H
• Yurchick Christopher L

Classifications

• H04W72/20

  Control channels or signalling for resource management · CPC title

• C01B32/05

  Preparation or purification of carbon not covered by groups C01B32/15, C01B32/20, C01B32/25, C01B32/30 · CPC title

• B82Y40/00

  Manufacture or treatment of nanostructures · CPC title

• C01P2002/82

  by IR- or Raman-data · CPC title

• C01P2004/61

  Micrometer sized, i.e. from 1-100 micrometer · CPC title