Direct Ink 3D Printing of Porous Carbon Monoliths for Gas Separations

Self-Supported Branched Poly(ethylenimine) Monoliths from Inverse Template 3D Printing for Direct Air Capture

3D-printed inverse templates are combined with ice templating to develop self-supported branched poly(ethylenimine) monoliths with regular channels of varying channel density and ordered macropores. A maximum uptake of 0.96 mmol of CO2/g of monolith from ambient air containing 45.5% RH is achieved from dynamic breakthrough experiments, which is a 31% increase compared to the CO2 uptake from adsorption under dry conditions for the same duration. The breakthrough experiments show characteristics of internal mass-transfer limitations. The cyclic dynamic breakthrough experiments indicate stable operation without significant loss in CO2 uptake across eight cycles. Moreover, the self-supported monolith shows minimal loss in adsorption capacity (7.7%) upon exposure to air containing 21% oxygen at 110 °C, in comparison to a conventional sorbent consisting of poly(ethylenimine) impregnated on Al2O3 (18.9%). The monoliths exhibit good mechanical stability, contributed by elastic deformation, corresponding to up to 74% strain and lower pressure drop compared to many existing monoliths in the literature.

Opportunities at the Intersection of 3D Printed Polymers and Pyrolysis for the Microfabrication of Carbon-Based Energy Materials

In an era marked by a growing demand for sustainable and high-performance materials, the convergence of additive manufacturing (AM), also known as 3D printing, and the thermal treatment, or pyrolysis, of polymers to form high surface area hierarchically structured carbon materials stands poised to catalyze transformative advancements across a spectrum of electrification and energy storage applications. Designing 3D printed polymers using low-cost resins specifically for conversion to high performance carbon structures via post-printing thermal treatments overcomes the challenges of 3D printing pure carbon directly due to the inability of pure carbon to be polymerized, melted, or sintered under ambient conditions. In this perspective, we outline the current state of AM methods that have been used in combination with pyrolysis to generate 3D carbon structures and highlight promising systems to explore further. As part of this endeavor, we discuss the effects of 3D printed polymer chemistry composition, additives, and pyrolysis conditions on resulting 3D pyrolytic carbon properties. Furthermore, we demonstrate the viability of combining continuous liquid interface production (CLIP) vat photopolymerization with pyrolysis as a promising avenue for producing 3D pyrolytic carbon lattice structures with 15 μm feature resolution, paving way for 3D carbon-based sustainable energy applications.

Photocatalytic NOx removal with TiO2-impregnated 3D-printed PET supports

In this work, we investigated the photocatalytic removal of NOx using 3D-printed supports. Monolithic supports with internal channels were fabricated by Fused Modelling Deposition (FDM) using PET as the filament feedstock. The printing parameters of the supports were optimized to maximize the exposure of the photocatalyst to UV light throughout the monolithic PET printed supports. The removal experiments were carried out in a continuous gas phase flow reactor, which was custom designed in-house incorporating a 3D printed PET support impregnated with TiO2 as photocatalyst. The impregnated and non-impregnated supports were characterized by diffuse reflectance spectrometry, SEM and AFM. The effect of several key-factors on the NOx removal capacity was investigated, including the type of PET filament (native recycled, BPET vs. glycol-modified, PETG), the type of TiO2 (P25 vs. Hombikat UV-100), the UV light source (LED vs. tubular lamps), and the number of deposited TiO2 layers. The highest NO and NOx removal were achieved by using PETG supports coated with a single layer of Hombikat UV-100 and irradiating the flat reactor from both sides using two sets of black light lamps. However, the highest selectivity toward nitrate formation was obtained when using P25 under the same experimental conditions. This work demonstrates that 3D printing is a reliable and powerful technique for fabricating photocatalytic reactive supports that can serve as a versatile platform for evaluating photocatalytic performance.

Hierarchical Biobased Macroporous/Mesoporous Carbon: Fabrication, Characterization and Electrochemical/Ion Exchange Properties

With the goal of improving the mechanical properties of porous hierarchical carbon, cellulosic fiber fabric was incorporated into the resorcinol/formaldehyde (RF) precursor resins. The composites were carbonized in an inert atmosphere, and the carbonization process was monitored by TGA/MS. The mechanical properties, evaluated by nanoindentation, show an increase in the elastic modulus due to the reinforcing effect of the carbonized fiber fabric. It was found that the adsorption of the RF resin precursor onto the fabric stabilizes its porosity (micro and mesopores) during drying while incorporating macropores. The textural properties are evaluated by N₂ adsorption isotherm, which shows a surface area (BET) of 558 m²g^-1. The electrochemical properties of the porous carbon are evaluated by cyclic voltammetry (CV), chronocoulometry (CC), and electrochemical impedance spectroscopy (EIS). Specific capacitances (in 1 M H₂SO₄) of up to 182 Fg^-1 (CV) and 160 Fg^-1 (EIS) are measured. The potential-driven ion exchange was evaluated using Probe Bean Deflection techniques. It is observed that ions (protons) are expulsed upon oxidation in acid media by the oxidation of hydroquinone moieties present on the carbon surface. In neutral media, when the potential is varied from values negative to positive of the potential of zero charge, cation release, followed by anion insertion, is found.

One-Pot Synthesis of Melamine Formaldehyde Resin-Derived N-Doped Porous Carbon for CO2 Capture Application

The design and synthesis of porous carbons for CO₂ adsorption have attracted tremendous interest owing to the ever-soaring concerns regarding climate change and global warming. Herein, for the first time, nitrogen-rich porous carbon was prepared with chemical activation (KOH) of commercial melamine formaldehyde resin (MF) in a single step. It has been shown that the porosity parameters of the as-prepared carbons were successfully tuned by controlling the activating temperature and adjusting the amount of KOH. Thus, as-prepared N-rich porous carbon shows a large surface area of 1658 m²/g and a high N content of 16.07 wt%. Benefiting from the unique physical and textural features, the optimal sample depicted a CO₂ uptake of up to 4.95 and 3.30 mmol/g at 0 and 25 °C under 1 bar of pressure. More importantly, as-prepared adsorbents show great CO₂ selectivity over N₂ and outstanding recyclability, which was prominently important for CO₂ capture from the flue gases in practical application. An in-depth analysis illustrated that the synergetic effect of textural properties and surface nitrogen decoration mainly determined the CO₂ capture performance. However, the textural properties of carbons play a more important role than surface functionalities in deciding CO₂ uptake. In view of cost-effective synthesis, outstanding textural activity, and the high adsorption capacity together with good selectivity, this advanced approach becomes valid and convenient in fabricating a unique highly efficient N-rich carbon adsorbent for CO₂ uptake and separation from flue gases.

One-Step Synthesis of Sulfur-Doped Nanoporous Carbons from Lignin with Ultra-High Surface Area, Sulfur Content and CO2 Adsorption Capacity

Lignin is the second-most available biopolymer in nature. In this work, lignin was employed as the carbon precursor for the one-step synthesis of sulfur-doped nanoporous carbons. Sulfur-doped nanoporous carbons have several applications in scientific and technological sectors. In order to synthesize sulfur-doped nanoporous carbons from lignin, sodium thiosulfate was employed as a sulfurizing agent and potassium hydroxide as the activating agent to create porosity. The resultant carbons were characterized by pore textural properties, X-ray photoelectron spectroscopy (XPS), X-ray diffraction (XRD), and scanning electron microscopy (SEM). The nanoporous carbons possess BET surface areas of 741-3626 m²/g and a total pore volume of 0.5-1.74 cm³/g. The BET surface area of the carbon was one of the highest that was reported for any carbon-based materials. The sulfur contents of the carbons are 1-12.6 at.%, and the key functionalities include S=C, S-C=O, and SO_x. The adsorption isotherms of three gases, CO₂, CH₄, and N₂, were measured at 298 K, with pressure up to 1 bar. In all the carbons, the adsorbed amount was highest for CO₂, followed by CH₄ and N₂. The equilibrium uptake capacity for CO₂ was as high as ~11 mmol/g at 298 K and 760 torr, which is likely the highest among all the porous carbon-based materials reported so far. Ideally adsorbed solution theory (IAST) was employed to calculate the selectivity for CO₂/N₂, CO₂/CH₄, and CH₄/N₂, and some of the carbons reported a very high selectivity value. The overall results suggest that these carbons can potentially be used for gas separation purposes.

One-Pot Synthesis of N-Rich Porous Carbon for Efficient CO2 Adsorption Performance

N-enriched porous carbons have played an important part in CO2 adsorption application thanks to their abundant porosity, high stability and tailorable surface properties while still suffering from a non-efficient and high-cost synthesis method. Herein, a series of N-doped porous carbons were prepared by a facile one-pot KOH activating strategy from commercial urea formaldehyde resin (UF). The textural properties and nitrogen content of the N-doped carbons were carefully controlled by the activating temperature and KOH/UF mass ratios. As-prepared N-doped carbons show 3D block-shaped morphology, the BET surface area of up to 980 m2/g together with a pore volume of 0.52 cm3/g and N content of 23.51 wt%. The optimal adsorbent (UFK-600-0.2) presents a high CO2 uptake capacity of 4.03 mmol/g at 0 °C and 1 bar. Moreover, as-prepared N-doped carbon adsorbents show moderate isosteric heat of adsorption (43-53 kJ/mol), acceptable ideal adsorption solution theory (IAST) selectivity of 35 and outstanding recycling performance. It has been pointed out that while the CO2 uptake was mostly dependent on the textural feature, the N content of carbon also plays a critical role to define the CO2 adsorption performance. The present study delivers favorable N-doped carbon for CO2 uptake and provides a promising strategy for the design and synthesis of the carbon adsorbents.