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BR-112021007837-B1 - Use of carbon nanomaterials produced with a low carbon footprint to produce composites with low CO2 emissions.

BR112021007837B1BR 112021007837 B1BR112021007837 B1BR 112021007837B1BR-112021007837-B1

Abstract

USE OF CARBON NANOMATERIALS PRODUCED WITH A LOW CARBON FOOTPRINT TO PRODUCE LOW CO2 EMISSION COMPOSITES. This involves a low-carbon footprint material used to reduce carbon dioxide emissions for the production of a high-carbon footprint substance. A method for forming composite materials comprises providing a first high-carbon footprint substance; providing a carbon nanomaterial produced with a carbon footprint of less than 10 weight units of carbon dioxide (CO2) emissions during the production of 1 weight unit of the carbon nanomaterial; and forming a composite comprising the high-carbon footprint substance and 0.001% by weight to 25% by weight of the carbon nanomaterial, wherein the carbon nanomaterial is homogeneously dispersed in the composite to reduce carbon dioxide emissions for the production of the composite material relative to the high-carbon footprint substance.

Inventors

  • Stuart Licht
  • Gad Licht

Assignees

  • C2CNT, LLC

Dates

Publication Date
20260310
Application Date
20191029
Priority Date
20181029

Claims (20)

  1. 1. A method for forming composite materials characterized in that it comprises the steps of: providing a high-carbon footprint substance; providing a carbon nanomaterial produced with a negative carbon footprint indicating a net consumption of carbon dioxide during the production of the carbon nanomaterial; and forming a composite comprising the high-carbon footprint substance and from 0.001% by weight to 25% by weight of the carbon nanomaterial, wherein the carbon nanomaterial is dispersed in the composite material to reduce carbon dioxide emissions for the production of the composite material relative to the high-carbon footprint substance and to increase the strength property of the composite material; wherein the carbon nanomaterial is formed from a molten carbonate by electrolysis.
  2. 2. Method according to claim 1, characterized in that the carbon nanomaterial comprises carbon nanofibers with an average aspect ratio of 10 to 1,000 and a thickness of 3 nm to 999 nm.
  3. 3. Method according to claim 1, characterized in that the nanofibers comprise one or more carbon nanotubes, helical carbon nanotubes, loose carbon nanofibers, carbon nano-onions, carbon nano-scaffolds, nano-platelets and graphene.
  4. 4. Method according to claim 1, characterized in that the formation step comprises adding the carbon nanomaterial to a solid phase or a liquid phase or a gaseous phase of the substance with a high carbon footprint.
  5. 5. Method according to claim 1, characterized in that the forming step comprises dispersing the carbon nanomaterial in a liquid to form a first mixture, mixing the first mixture with the high-carbon footprint substance to form a second mixture, and forming the composite material from the second mixture.
  6. 6. Method according to claim 1, characterized in that the molten carbonate is generated by a reaction of carbon dioxide and a metal oxide in a molten electrolyte.
  7. 7. Method according to claim 6, characterized in that the metal oxide is lithium oxide.
  8. 8. Method according to claim 1, characterized in that the molten carbonate comprises a lithium carbonate or a lithium-containing carbonate.
  9. 9. Method according to claim 1, characterized in that the substance with a high carbon footprint comprises one or more cement, concrete, mortar or plaster.
  10. 10. Method according to claim 1, characterized in that the substance with a high carbon footprint comprises a metal.
  11. 11. Method according to claim 1, characterized in that the substance with a high carbon footprint comprises a plastic material, a resin, a ceramic, a glass, an insulator, an electrical conductor, a polymer, wood, a laminate, cardboard and a gypsum board.
  12. 12. Method for forming composite materials characterized in that it comprises the steps of: providing a high-carbon footprint substance; forming a carbon nanomaterial produced from a molten carbonate by electrolysis, wherein the carbon nanomaterial has a carbon footprint of less than 10 weight units of carbon dioxide (CO2) emissions during the production of 1 weight unit of the carbon nanomaterial; forming a dispersion of the carbon nanomaterial by sonication, agitation, or a combination thereof of the carbon nanomaterial in a liquid without dissolving any additives in the dispersion; and adding the dispersion to the high-carbon footprint substance to form a composite comprising the high-carbon footprint substance and from 0.001% by weight to 25% by weight of the carbon nanomaterial, wherein the carbon nanomaterial is dispersed in the composite material to reduce carbon dioxide emissions for the production of the composite material relative to the high-carbon footprint substance and to increase the strength property of the composite material.
  13. 13. Method according to claim 12, characterized in that the carbon footprint is negative, indicating a net consumption of carbon dioxide during the production of the carbon nanomaterial.
  14. 14. Method according to claim 12, characterized in that the carbon nanomaterial comprises carbon nanofibers with an average aspect ratio of 10 to 1,000 and a thickness of 3 nm to 999 nm.
  15. 15. Method according to claim 14 characterized in that the nanofibers comprise one or more carbon nanotubes, helical carbon nanotubes, loose carbon nanofibers, carbon nano-onions, carbon nano-scaffolds, nano-platelets and graphene.
  16. 16. Method according to claim 12, characterized in that the formation step comprises adding the carbon nanomaterial to a solid phase or a liquid phase or a gaseous phase of the substance with a high carbon footprint.
  17. 17. Method according to claim 12, characterized in that the forming step comprises dispersing the carbon nanomaterial in a liquid to form a first mixture, mixing the first mixture with the high-carbon footprint substance to form a second mixture, and forming the composite material from the second mixture.
  18. 18. Method according to claim 12, characterized in that the molten carbonate is generated by a reaction of carbon dioxide and a metal oxide in a molten electrolyte.
  19. 19. Method according to claim 18, characterized in that the metal oxide is lithium oxide.
  20. 20. Method according to claim 12, characterized in that the molten carbonate comprises a lithium carbonate or a lithium-containing carbonate.

Description

CROSS-REFERENCE TO RELATED REQUESTS [0001] This application claims priority and benefits of Provisional Patent Application Serial No. U.S. 62/752,124, filed October 29, 2018, entitled “Massively amplified carbon cycle GHG CO2 removal with C2CNT carbon nanotube-composites”, and Provisional Patent Application Serial No. U.S. 62/890,719, filed August 23, 2019, “Massively amplified carbon cycle GHG CO2 removal with C2CNT carbon nanotube-composites”, the entire content of each of which is incorporated herein by reference. FIELD [0002] The present invention relates to the use of carbon nanomaterials produced with a low carbon footprint to produce composites with low CO2 emissions and related methods. BACKGROUND [0003] Structural materials, such as cement, metal, or similar materials, are useful in various applications and industries. For example, cement and metal are useful for the construction of buildings, bridges, and roads; and metals are useful for the production of vehicles and industrial and consumer appliances. A suitable structural material for a specific application may require certain mechanical strength and other physical properties, which may place limitations on the design and cost of a given construction project or product. The widespread use of structural materials is a substantial contributor to global carbon dioxide emissions and climate change. Additives for structural materials can form composites, alloys, or mixtures with improved desirable properties; laminates, insulation, or gypsum board can form composites, alloys, or mixtures with improved desirable properties. [0004] It is often desirable to enhance the properties of a structural material by means of additives to form composites, alloys, or mixtures with improved desirable properties. Examples of desirable properties include tensile, compressive, and flexural strength and durability. Similarly, additives for other materials, such as electrical conductors, glass, ceramics, paper, resin, polymer or plastics, cardboard laminates, insulators, or gypsum board, can form composites, alloys, or mixtures with improved desirable properties. Examples of properties include electrical conductivity or insulation, thermal conductivity or insulation, small volume or weight, fracture resistance, flexibility, and strength. [0005] Additives for forming composites with enhanced desirable properties can also have disadvantages, including technical complexity, such complexity in forming the composite, lack of desired properties in the additive, lack of homogeneity in the additive, complexity in scaling up, or scarcity of the additive, making the cost of the composite prohibitive and increasing carbon dioxide emissions in its production, which contributes to global carbon dioxide emissions and climate change. Furthermore, the production of virgin structural materials, or electrical conductors, glass, ceramics, paper, polymers, plastic resins, cardboard laminates, insulators, or gypsum board, is often associated with a high carbon footprint. For example, typical stainless steel production has a carbon footprint of 6.15 tons of CO2 emitted per ton of steel produced. Aluminum production typically emits 11.9 tons of CO2 per ton of product; titanium production typically emits 8.1 tons of CO2 per ton of product; Magnesium production typically emits 14 tons of CO2 per ton of product, and copper production emits 5 tons of CO2 per ton of product. Often, it is desirable to produce a material with a reduced carbon footprint. A reduced carbon footprint emits less carbon dioxide, a greenhouse gas. Carbon dioxide contributes to climate change, which has adverse effects including global warming, rising sea levels, drought, floods, severe weather events, economic loss, adverse health effects, and habitat loss and species extinction. SUMMARY [0006] This disclosure relates to methods of combining a high-carbon footprint substance, such as structural materials like cement, metal, wood or the like, or electrical conductors, glass, ceramics, paper, polymer or plastic, cardboard laminates, insulators or gypsum board, to form a low-carbon footprint composite, readily mixable carbon nanomaterials, industrially scalable and economical to reduce carbon dioxide emissions for the production of the composite material relative to the high-carbon footprint substance. [0007] In one aspect, a method is provided for forming materials with a reduced carbon footprint, comprising providing a first substance with a high carbon footprint to be converted into a composite with improved properties (or properties); providing a material comprising a carbon nanomaterial produced with a carbon footprint of less than 10 weight units of carbon dioxide (CO2) emissions during the production of 1 weight unit of the carbon nanomaterial; and forming a composite comprising the first structural material and from 0.001% by weight to 25% by weight of the carbon nanomaterial, wherein the carbon nanomaterial is homog