Porous carbon materials derived from discarded COVID-19 masks via microwave solvothermal method for lithium‑sulfur batteries

Accurate additive manufacturing of lightweight and elastic carbons using plastic precursors

Despite groundbreaking advances in the additive manufacturing of polymers, metals, and ceramics, scaled and accurate production of structured carbons remains largely underdeveloped. This work reports a simple method to produce complex carbon materials with very low dimensional shrinkage from printed to carbonized state (less than 4%), using commercially available polypropylene precursors and a fused filament fabrication-based process. The control of macrostructural retention is enabled by the inclusion of fiber fillers regardless of the crosslinking degree of the polypropylene matrix, providing a significant advantage to directly control the density, porosity, and mechanical properties of 3D printed carbons. Using the same printed plastic precursors, different mechanical responses of derived carbons can be obtained, notably from stiff to highly compressible. This report harnesses the power of additive manufacturing for producing carbons with accurately controlled structure and properties, while enabling great opportunities for various applications.

Towards environmentally sustainable management: A review on the generation, degradation, and recycling of polypropylene face mask waste

There has been a considerable increase in the use of face masks in the past years. Managing face mask waste has become a global concern, as the current waste management system is insufficient to deal with such a large quantity of solid waste. The drastic increase in quantity, along with the material's inability to degrade plastic components such as polypropylene, has led to a large accumulation of plastic waste, causing a series of environmental and ecological challenges. In addition, the growing use also imposes pressure on waste management methods such as landfill and incineration, raising concerns about high energy consumption, low value-added utilization, and the release of additional pollutants during the process. This article initially reviews the impact of mask-related plastic waste generation and degradation behavior in the natural environment. It then provides an overview of various recently developed methods for recycling face mask plastic waste. The article also offers forward-looking strategies and recommendations on face mask plastic waste management. The review aims to provide guidance on harnessing the complexities of mask waste and other medical plastic pollution issues, as well as improving the current waste management system's deficiencies and inefficiencies in tackling the growing plastic waste problem.

Three birds, one stone: Disinfecting and turning waste medical masks into valuable carbon dots for sodium hydrosulfite and Fe3+ detection enabled by a simple hydrothermal treatment

Disposable medical masks are widely used to prevent respiratory infections due to their ability to block virus particles from entering the human body. The coronavirus disease 2019 (COVID-19) pandemic highlighted the importance of medical masks, leading to their widespread use around the world. However, a large number of disposable medical masks have been discarded, some carrying viruses, which have posed a grave threat to the environment and people's health, as well as wasting resources. In this study, a simple hydrothermal method was used for the disinfection of waste medical masks under high-temperature conditions as well as for their transformation into high-value-added carbon dots (CDs, a new type of carbon nanomaterial) with blue-emissive fluorescence, without high energy consumption or environmental pollution. Moreover, the mask-derived CDs (m-CDs) could not only be used as fluorescent probes for sensing sodium hydrosulfite (Na₂S₂O₄), which is widely used in the food and textile industries but is seriously harmful to human health, but also be used for detecting Fe³⁺ which is harmful to the environment and human health due to its wide use in industries.

Sustainable Solution for Plastic Pollution: Upcycling Waste Polypropylene Masks for Effective Oil-Spill Management

The use of Polypropylene PP in disposable items such as face masks, gloves, and personal protective equipment has increased exponentially during and after the COVID-19 pandemic, contributing significantly to microplastics and nanoplastics in the environment. Upcycling of waste PP provides a useful alternative to traditional thermal and mechanical recycling techniques. It transforms waste PP into useful products, minimizing its impact on the environment. Herein, we synthesized an oil-sorbent pouch using waste PP, which comprises superposed microporous and fibrous thin films of PP using spin coating. The pouch exhibited super-fast uptake kinetics and reached its saturation in fewer than five minutes with a high oil uptake value of 85 g/g. Moreover, it displayed high reusability and was found to be effective in absorbing oil up to seven times when mechanically squeezed between each cycle, demonstrating robust oil-sorption capabilities. This approach offers a potential solution for managing plastic waste while promoting a circular economy.

Activated carbons derived from polyethylene terephthalate for coin-cell supercapacitor electrodes

We successfully prepared activated carbon derived from polyethylene terephthalate (PET) via carbonization and subsequent activation under various conditions and applied it as active material for supercapacitors. In the activation, we used CO2 for physical activation or KOH for chemical activation and varied the activation temperature from 600 °C to 1,000 °C. We found that CO2 activation is unsuitable because of insufficient pore formation or low activation yield. Interestingly, PET-derived activated carbon obtained using KOH (PETK) at 700 °C-900 °C exhibited higher specific surface areas than YP50f, which is a commercial activated carbon. Furthermore, some PETKs even displayed a dramatic increase in crystallinity. In particular, the PET-derived activated carbon prepared at 900 °C with KOH (PETK900) had the highest retention rate at a high charge-discharge rate and better durability after 2500 cycles than YP50f. Furthermore, employing the same process that we used with the PET chips, we successfully converted waste PET bottles into activated carbon materials. Waste PET-derived activated carbons exhibited good electrochemical performance as active material for supercapacitors. We thus found chemical activation with KOH to be an appropriate method for manufacturing PET-derived activated carbon and PETKs derived both from PET chips and waste PET have considerable potential for commercial use as active materials for supercapacitors.

Electronic Supplementary Material

Supplementary material is available for this article at 10.1007/s11814-023-1466-3 and is accessible for authorized users.

Advanced and Smart Textiles during and after the COVID-19 Pandemic: Issues, Challenges, and Innovations

The COVID-19 pandemic has hugely affected the textile and apparel industry. Besides the negative impact due to supply chain disruptions, drop in demand, liquidity problems, and overstocking, this pandemic was found to be a window of opportunity since it accelerated the ongoing digitalization trends and the use of functional materials in the textile industry. This review paper covers the development of smart and advanced textiles that emerged as a response to the outbreak of SARS-CoV-2. We extensively cover the advancements in developing smart textiles that enable monitoring and sensing through electrospun nanofibers and nanogenerators. Additionally, we focus on improving medical textiles mainly through enhanced antiviral capabilities, which play a crucial role in pandemic prevention, protection, and control. We summarize the challenges that arise from personal protective equipment (PPE) disposal and finally give an overview of new smart textile-based products that emerged in the markets related to the control and spread reduction of SARS-CoV-2.

Additive Manufacturing of Carbon Using Commodity Polypropylene

Carbon materials are essential to the development of modern society with indispensable use in various applications, such as energy storage and high-performance composites. Despite great progress, on-demand carbon manufacturing with control over 3D macroscopic configuration is still an intractable challenge, hindering their direct use in many areas requiring structured materials and products. This work introduces a simple and scalable method to generate complex, large-scale carbon structures using easily accessible materials and technologies. 3D-printed, commercial polypropylene (PP) parts can be thermally stabilized through cracking-facilitated diffusion and crosslinking. The newly elucidated mechanism from this work allows thick PP parts to yield carbonaceous products with complex structures through a subsequent pyrolysis step. The approach for enabling PP-to-carbon conversion has consistent product yield and controlled dimensional shrinkage. Under optimized processing conditions, these PP-derived carbons exhibit robust mechanical properties and excellent joule heating performance, demonstrated by their versatile use as heating elements. Furthermore, this process can be extended to recycled PP, enabling the conversion of waste plastic materials to value-added products. This work provides an innovative approach to create structured carbon materials with direct access to complex geometry, which can be transformative to, and broadly benefit, many important technological applications.

Disposal and resource utilization of waste masks: a review

Waste masks pose a serious threat to the environment, including marine plastic pollution and soil pollution risks caused by landfills since the outbreak of COVID-19. Currently, numerous effective methods regarding disposal and resource utilization of waste masks have been reported, containing physical, thermochemical, and solvent-based technologies. As for physical technologies, the mechanical properties of the mask-based materials could be enhanced and the conductivity or antibacterial activity was endowed by adding natural fibers or inorganic nanoparticles. Regarding thermochemical technologies, catalytic pyrolysis could yield considerable hydrogen, which is an eco-friendly resource, and would mitigate the energy crisis. Noticeably, the solvent-based technology, as a more convenient and efficient method, was also considered in this paper. In this way, soaking the mask directly in a specific chemical reagent changes the original structure of polypropylene and obtains multi-functional materials. The solvent-based technology is promising in the future with the researches of sustainable and universally applicable reagents. This review could provide guidance for utilizing resources of waste masks and address the issues of plastic pollution.

Upcycling face mask wastes generated during COVID-19 into value-added engineering materials: A review

Billions of disposable face masks (i.e., single-use masks) are used and discarded worldwide monthly due to the COVID-19 outbreak. The immethodical disposal of these polymer-based wastes containing non-biodegradable constituents (e.g., polypropylene) has provoked marked and severe damage to the ecosystem. Meanwhile, their ever-growing usage significantly strains the present-day waste management measures such as landfilling and incineration, resulting in large quantities of used face-covering masks landing in the environment as importunate contaminants. Hence, alternative waste management strategies are crucially demanded to decrease the negative impacts of face mask contamination. In this venue, developing high-yield, effective, and green routes toward recycling or upcycling face mask wastes (FMWs) into value-added materials is of great importance. While existing recycling processes assist the traditional waste management, they typically end up in materials with downgraded physicochemical, structural, mechanical, and thermal characteristics with reduced values. Therefore, pursuing potential economic upcycling processes would be more beneficial than waste disposal and/or recycling processes. This paper reviews recent advances in the FMWs upcycling methods. In particular, we focus on producing value-added materials via various waste conversion methods, including carbonization (i.e., extreme pyrolysis), pyrolysis (i.e., rapid carbonization), catalytic conversion, chemical treatment, and mechanical reprocessing. Generally, the upcycling methods are promising, firming the vital role of managing FMWs' fate and shedding light on the road of state-of-the-art materials design and synthesis.

Synthesis of Sulfonated Carbon from Discarded Masks for Effective Production of 5-Hydroxymethylfurfural

5-hydroxymethylfurfural (HMF), as one of the top ten important platform chemicals, can be used to produce 2,5-furandicarboxylic acid (FDCA), 2,5-dimethyl furan (DMF), levulinic acid, and other chemicals. An environmentally friendly system for the synthesis of sulfonated carbon materials from discarded masks has been proposed. A series of mask-based solid acid catalysts (bMC-SO3H) were prepared by a simple two-step process. Mechanochemical pretreatment (ball milling) of waste mask and sulfonated group precursor, followed by thermal carbonization under nitrogen gas, were used to synthesize sulfonated porous carbon. The total acid amount of the prepared bMC-SO3H was measured by the Boehm method, which exhibited 1.2–5.3 mmol/g. The addition of the sulfonated group precursor in the mechanochemical treatment (ball milling) process caused intense structure fragmentation of the discarded masks. These sulfonated porous carbons (bMC(600)-SO3H) as solid acid catalysts achieved fructose conversion of 100% and HMF yield of 82.1% after 120 min at 95 °C in 1-butyl-3-methylimidazolium chloride. The bMC-SO3H could be reused five times, during which both the HMF yield and fructose conversion were stable. This work provides a strategy for the synthesis of sulfonated carbon from discarded masks and efficient catalyzed fructose upgrading to HMF.

Structure-oriented conversions of plastics to carbon nanomaterials

The accumulation of waste plastics has caused serious environmental issues due to their unbiodegradable nature and hazardous additives. Converting waste plastics to different carbon nanomaterials (CNMs) is a promising approach to minimize plastic pollution and realize advanced manufacturing of CNMs. The reported plastic-derived carbons include carbon filaments (i.e. carbon nanotubes and carbon nanofibers), graphene, carbon nanosheets, carbon sphere, and porous carbon. In this review, we present the influences of different intrinsic structures of plastics on the pyrolysis intermediates. We also reveal that non-charring plastics are prone to being pyrolyzed into light hydrocarbons while charring plastics are prone to being pyrolyzed into aromatics. Subsequently, light hydrocarbons favor to form graphite while aromatics are inclined to form amorphous carbon during the carbon formation process. In addition, the conversion tendency of different plastics into various morphologies of carbon is concluded. We also discuss other impact factors during the transformation process, including catalysts, temperature, processing duration and templates, and reveal how to obtain different morphological CNMs from plastics. Finally, current technology limitations and perspectives are presented to provide future research directions in effective plastic conversion and advanced CNM synthesis.

The impact factors in transforming plastics into carbon nanomaterials are reviewed.

The carbon morphology tendency from different plastics is revealed.

Directions for future research on plastic carbonization are presented.

Discarded COVID-19 masks-derived-doped porous carbon for lithium-sulfur batteries

Despite the high theoretical capacity and energy density of lithium-sulfur (Li-S) batteries, the development of Li-S batteries has been slow due to the poor electrical conductivity and the shuttle effect of the electrode materials, resulting in low sulfur utilization and fast long-term cycling capacity decay. The modified carbon materials are often used as sulfur hosts to significantly improve the cycling performance of the materials, but also bring high-cost issues. Here, the porous carbon materials are synthesized quickly and conveniently by the microwave cross-linking method using discarded medical masks as carbon sources and concentrated sulfuric acid as solvent. However, poor surface and structural properties limit the application of materials. The porous carbon material is modified with p-toluene disulfide and urea as the sulfur and nitrogen sources by the microwave cross-linking method, which not only improves the porosity and specific surface area of the porous carbon material, but also improved the electrical conductivity and interlayer spacing of the material. As synthesized SN-doped porous carbon is employed as the sulfur host, which exhibits a high discharge capacity (1349.3 mAh g-1) at 0.1°C, the S-porous C/S, N-porous C/S, and SN-porous C/S can maintain 78.1, 43.9, and 59.5% of the initial capacity after 500 cycles. The results indicate that the doping of S and N atoms provides sufficient active sites for the chemisorbed lithium polysulfides (LiPSs) to improve the reaction kinetics of the materials.