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Materials Design of Coal to Products
Jeffrey C. Grossman
Department of Materials Science and EngineeringMassachusetts Institute of Technology
NCC 2020 Fall Annual Meeting | 10.23.2020
Coal as a feedstock material: Certainly not a new idea
medicines
photography
paint
insecticides
Billiard balls
linoleum
baking powder
(1930)
A souvenir made by 6th graders from Huntington, West Virginia, for then senator JF Kennedy
How can we apply modern materials design tools to unlock the rich chemistry in natural carbon as a cheap, highly adaptable feedstock?
B. Keller, N. Ferralis, J.C. Grossman. Nano Lett. 2016, 16, 5, 2951–2957
Coal
Annealing
Conductivity better than reduced graphene
4
Brent Keller
Nicola Ferralis
Comparing Coal to Tar
5
• “Steam-cracker” tar is a carbon waste product• Literally “bottom of the barrel” burned or given away
Oven annealing
Transparent heaters from Tar
O. Morris et al. Adv. Mater. 2019, 31, 1900331 6
Owen Morris
Xining Zhang
Nicola Ferralis
Laser Processing of tar
O. Morris et al. Adv. Mater. 2019, 31, 1900331 7
Local heating of the laser:
• suitable for different substrates
• compatible with lithography processes
Expanding the toolbox of hydrocarbons
Tar Pitch
(mesophase)
Coal
0.14
0.66
0.780.83
1
0.64
Initial Final 0.0
0.2
0.4
0.6
0.8
1.0
1.2
1.4
Sp
2
Tar
Coal
Mesophase
1.84
1.14
0.59
0.34
0.580.52
Initial Final 0.0
0.4
0.8
1.2
1.6
2.0
H:C
Tar
Coal
Mesophase
C. Jian, X.Zang, N Ferralis, JC Grossman, Carbon, 155, 309 (2019)
X. Zang et al., Sci. Adv. 2020; 6 : eaaz5231 Xining Zhang Nicola Ferralis
Different carbon feedstocks can be combined to control properties.
0 20 40 60 80 1000.2
0.4
0.6
0.8
1.0
ID/IGID
/IG
La (A)
X. Zang et al., Sci. Adv. 2020; 6 : eaaz5231
graphene Diameter (A)
Xining Zhang Nicola Ferralis
Can control sp3 fraction, graphene flake size & stacking over a broad range
grap
hen
e St
acki
ng
Different mixtures / laser power
Silicon QuantumDots
Manufacturing complexity▪ Simple Materials
▪ Complex Fabrication
▪ Complex Materials
▪ Simple fabrication
V. Bulovic. Energ Environ Sci 8, 1200, 2015
Natural carbon (coal, pitch, tar, etc.):• Materials complexity, high heterogeneity • Massive tunability• Can tailor manufacturing to application• Ultra-cheap
coal
Coal with a laser and deeper understanding
Anthracite
Bituminous
Lignite
Molecular Representation Coal Microstructure Laser Annealed Coal
Coal maturity + laser + additives lead to massive control over:• Electronic
properties• Magnetic
properties• Structural
properties
X. Zang et al. Submitted (2020). 13
Printed Coal Electronics
Printed metal powder in air with coal/tar binder
Xining Zhang
Nicola Ferralis
Laser Engineered Coal (R-2-R)
Pressing
First Bath Substrate Cleaning Second Bath Functionalization
Inkjet Printing/Spraying
Ball milling
Dispersion
Solution/surfactant
Drying
Third Bath Binder Structure, porosity, conductivity and etc
Doping
Develop solution based coating, and integrate fiber laser for R-2-R manufacturing.
Layer 1
Layer 2
Photo credit: Bernard Gagnon, CC BY-SA 3.0,
https://commons.wikimedia.org/w/index.php?curid=25603883
Camel fur helps to keep camels cool!
Can we do as well as a camel?
Large-area application example #1: functional coatings
Large-area application example #1: functional coatings
• The cost bottleneck is
the aerogel. Can we
make a coal-based
aerogel?
• Cheap thermal coatings
made from coal could
make this technology
scalable.
Two Ways to Separate Pasta
Membrane Thermal>80% Energy savings
Large-area application example #2: membranes
★Sugars★Small proteins★Amino acids★Molecular chemicals★Antibiotics★Dissolved salts★Acids★Bases★Dissolved oils★Dyes
US Energy Consumption (2015)
Industry
32%Transportation
28%
Commercial
18%Residential
22%
Evaporation & Distillation 40%12 quadrillion BTU
★ Desalination
Two Ways to Separate 1-10 nm Particles
Howard Perlman, USGS, NOAA Drought Monitor, 2016
accessible freshwater
available seawater Switch from
thermal to
membrane
based
24
Shreya Dave
Brent Keller
24
ViaSeparations
6000x scale-up
Cost-Effective, Robust, Graphene-basedfiltrations for Industrial Applications
D. Cohen-Tanugi et al. Energy Environ. Sci., 2014, 7, 1134S. Dave, B. Keller, K. Golmer, and JCG, Joule 2017
50th Percentile for each technology, IPCC Special Report on Renewable Energy Sources and Climate Change Mitigation 27
Coal
different^
…by understanding its atomic-scale chemistry and leveraging its flexibility as a feedstock for advanced manufacturing of new, functional, robust, cheap materials.