US 2024/0301591 A1 · SYSTEMS, METHODS, AND DEVICES FOR CARBON MATERIAL UPGRADE AND ORGANIC COMPOUND PYROLYSIS

Abstract

A carbon material can comprise a porous scaffold of carbon fibrils and particles of carbon black attached to the carbon fibrils. The carbon material can be provided in an atmosphere of a gas comprising one or more organic compounds, for example, methane. The carbon material and the gas can be subjected to a temperature (e.g., 1700 K) that causes the organic compound(s) to undergo pyrolysis to form carbon and hydrogen. For example, the carbon material can be used as a Joule heating element to heat the material and the gas to the pyrolysis temperature. At least some of the formed carbon can be deposited on or within the carbon material. As a result, the carbon fibrils in the material can merge to form a carbonized matrix, and the carbon black particles can become embedded within the carbonized matrix.

Claims27

Dependent claims

A method comprising:

(a) providing a first material comprising a porous scaffold of carbon fibrils and particles of carbon black attached to the carbon fibrils;
and
(b) subjecting the first material, in a first atmosphere of a gas comprising one or more organic compounds, to a pyrolysis temperature for a first duration, such that:
the one or more organic compounds undergo pyrolysis to form carbon and hydrogen, at least some of the formed carbon being deposited on, within, or both on and within the first material,
the carbon fibrils merge to form a carbonized matrix, and
the carbon black particles become embedded within the carbonized matrix.

3 more elements

A system comprising:

a gas enclosure constructed to contain a first atmosphere of a gas comprising one or more organic compounds;
an inlet line comprising one or more inlet flow control devices and constructed to deliver the gas to the gas enclosure;
a pair of electrodes disposed within the gas enclosure and constructed to be coupled to respective portions of one or more first materials;
a current source coupled to the pair of electrodes;
and
a controller operatively coupled to the one or more inlet flow control devices and the current source, the controller comprising one or more processors and computer-readable storage media storing instructions that, when executed by the one or more processors, cause the controller to:
control the one or more inlet flow control devices to provide the first atmosphere to the gas enclosure;
and
control the current source to pass a first electrical current through at least part of each first material via the pair of electrodes so as to subject the at least part of each first material in the first atmosphere to a pyrolysis temperature for a first duration,
wherein the subjecting to the pyrolysis temperature is such that:
the one or more organic compounds undergo pyrolysis to form carbon and hydrogen, at least some of the formed carbon being deposited on, within, or both on and within the at least part of each first material,
carbon fibrils within the at least part of each first material merge to form a respective carbonized matrix, and
carbon black particles within the at least part of each first material become embedded within the respective carbonized matrix.

10 more elements

Dependencies are inferred from the claim text.

Systems, methods, and devices for carbon material upgrade and organic compound pyrolysis

Life of this patent

Systems, methods, and devices for carbon material upgrade and organic compound pyrolysis

Life of this patent

Abstract

Claims27