Electron correlation strengthened in multilayer rhombohedral graphite
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Flash Joule heating for synthesis, upcycling and remediation
Electric heating methods are being developed and used to electrify industrial applications and lower their carbon emissions. Direct Joule resistive heating is an energy-efficient electric heating technique that has been widely tested at the bench scale and could replace some energy-intensive and carbon-intensive processes. In this Review, we discuss the use of flash Joule heating (FJH) in processes that are traditionally energy-intensive or carbon-intensive. FJH uses pulse current discharge to rapidly heat materials directly to a desired temperature; it has high-temperature capabilities (>3,000 °C), fast heating and cooling rates (>102 °C s−1), short duration (milliseconds to seconds) and high energy efficiency (~100%). Carbon materials and metastable inorganic materials can be synthesized using FJH from virgin materials and waste feedstocks. FJH is also applied in resource recovery (such as from e-waste) and waste upcycling. An emerging application is in environmental remediation, where FJH can be used to rapidly degrade perfluoroalkyl and polyfluoroalkyl substances and to remove or immobilize heavy metals in soil and solid wastes. Life-cycle and technoeconomic analyses suggest that FJH can reduce energy consumption and carbon emissions and be cost-efficient compared with existing methods. Bringing FJH to industrially relevant scales requires further equipment and engineering development.
Enhanced energy storage in relaxor (1-x)Bi0.5Na0.5TiO3-xBaZryTi1-yO3 thin films by morphotropic phase boundary engineering
Perovskites at the crossover between ferroelectric and relaxor are often used to realize dielectric capacitors with high energy and power density and simultaneously good efficiency. Lead-free Bi0.5Na0.5TiO3 is gaining importance in showing an alternative to lead-based devices. Here we show that (1-x)Bi0.5Na0.5TiO3 – xBaZryTi1-yO3 (best: 0.94Bi0.5Na0.5TiO3 -0.06BaZr0.4Ti0.6O3) shows an increase of recoverable energy density and electric breakdown upon chemical substitution. In thin films derived from Chemical Solution Deposition, we observed that polarization peaks at the morphotropic phase boundary at x = 0.06. While Zr substitution results in reduced polarization, it enhances both efficiency and electric breakdown strength, ultimately doubling the recoverable energy density and the metallization interface by lowering surface roughness. Our dielectric capacitor shows <3% deviation of energy properties over 106 cycles. A virtual device model of a multilayer thin film capacitor (7.25 mJ recoverable energy) was used to compare its performance to already in use multilayer ceramic capacitors.
The evolution of lithium-ion battery recycling
Demand for lithium-ion batteries (LIBs) is increasing owing to the expanding use of electrical vehicles and stationary energy storage. Efficient and closed-loop battery recycling strategies are therefore needed, which will require recovering materials from spent LIBs and reintegrating them into new batteries. In this Review, we outline the current state of LIB recycling, evaluating industrial and developing technologies. Among industrial technologies, pyrometallurgy can be broadly applied to diverse electrode materials but requires operating temperatures of over 1,000 °C and therefore has high energy consumption. Hydrometallurgy can be performed at temperatures below 200 °C and has material recovery rates of up to 93% for lithium, nickel and cobalt, but it produces large amounts of wastewater. Developing technologies such as direct recycling and upcycling aim to increase the efficiency of LIB recycling and rely on improved pretreatment processes with automated disassembly and cleaner mechanical separation. Additionally, the range of materials recovered from spent LIBs is expanding from the cathode materials recycled with established methods to include anode materials, electrolytes, binders, separators and current collectors. Achieving an efficient recycling ecosystem will require collaboration between recyclers, battery manufacturers and electric vehicle manufacturers to aid the design and automation of battery disassembly lines.
Advanced electrode processing for lithium-ion battery manufacturing
Lithium-ion batteries (LIBs) need to be manufactured at speed and scale for their use in electric vehicles and devices. However, LIB electrode manufacturing via conventional wet slurry processing is energy-intensive and costly, challenging the goal to achieve sustainable, affordable and facile manufacturing of high-performance LIBs. In this Review, we discuss advanced electrode processing routes (dry processing, radiation curing processing, advanced wet processing and 3D-printing processing) that could reduce energy usage and material waste. Maxwell-type dry processing is a scalable alternative to conventional processing and has relatively low manufacturing cost and energy consumption. Radiation curing processing could enable high-throughput manufacturing, but binder selection is limited to certain radiation curable chemistries. 3D-printing processing can produce electrodes with diverse architectures and improved rate performance, but scalability is yet to be demonstrated. 3D-printing processing is good for special applications where throughput and cost can be compromised for performance.
Printable graphene inks with polypropylene carbonate for low-surface-tension solvents and mild-temperature post-processing
For dispersion stability, printable graphene inks commonly employ solvents with limited surface tensions or incorporate dispersant aids that require high-temperature post-processing, restricting printability and substrate compatibility. Here, printable graphene inks are introduced with low-surface-tension solvents and mild-temperature post-processing using polypropylene carbonate (PPC). Graphene is produced by liquid-phase exfoliation with PPC, and the exfoliated graphene/PPC is used to generate printable inks. As a dispersant aid, PPC improves graphene exfoliation, dispersion stability, and redispersability in solvents with low surface tensions (<30 mJ m–2), facilitating the formulation of desirable inks for efficient aerosol jet printing on diverse substrates. Moreover, the low decomposition temperature of PPC eases its thermal removal from printed graphene, allowing high electrical conductivity with a mild post-processing temperature of 220 °C. Consequently, the graphene inks enable the fabrication of fully-printed graphene micro-supercapacitors on heat-sensitive paper substrates, exhibiting high areal capacitances, cycling stability, and mechanical resilience against bending deformation.
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