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US-20260128238-A1 - USE OF ZEOLITE-TEMPLATED CARBON (ZTCS) AS ELECTRODES FOR SUPERCAPACITORS

US20260128238A1US 20260128238 A1US20260128238 A1US 20260128238A1US-20260128238-A1

Abstract

ZTCs are used as active material for electrodes for supercapacitors. The ZTCs are generated from CaX or NaX templates. Carbon vapor deposition is performed utilizing acetylene, ethanol, or propylene. The ZTC-zeolite composition is graphitized, cooled, and undergoes an acid wash to remove the zeolite template. The ZTC generated from the process features a high surface area, and is operable for use as an active material in a supercapacitor. The supercapacitor can also feature an H 2 SO 4 electrolyte.

Inventors

  • Yuguo Wang
  • Ahmad D. HAMMAD
  • Rashid Othman

Assignees

  • SAUDI ARABIAN OIL COMPANY

Dates

Publication Date
20260507
Application Date
20221003

Claims (20)

  1. 1 . A method for generating a zeolite-templated carbon (ZTC) for use as an active material in an electrode in a supercapacitor, the method comprising the steps of: providing a CaX zeolite at a select size; performing carbon vapor deposition on the CaX zeolite in a plug-flow reactor using an organic precursor to generate a ZTC-zeolite composition, wherein the carbon vapor deposition occurs at an elevated temperature; cooling the ZTC-zeolite composition; then heating the ZTC-zeolite composition by introducing an inert gas stream for a defined period of time, wherein the ZTC is heated to a graphitizing temperature in the range of 820 K to 1180 K, to generate a graphitized ZTC-zeolite composition; cooling the graphitized ZTC-zeolite composition; and washing the graphitized ZTC-zeolite composition with acid to generate a prepared ZTC, the prepared ZTC having a select surface area and operable for use as an active material in an electrode in a supercapacitor.
  2. 2 . The method of claim 1 , wherein the inert gas stream comprises helium.
  3. 3 . The method of claim 1 , wherein the inert gas stream comprises nitrogen.
  4. 4 . The method of claim 1 , wherein the organic precursor is selected from the group consisting of: propylene, ethanol, acetylene, and combinations of the same.
  5. 5 . The method of claim 1 , wherein the organic precursor comprises propylene.
  6. 6 . The method of claim 1 , wherein the acid is selected from the group consisting of: HCl, HF, and combinations of the same.
  7. 7 . The method of claim 1 , further comprising the step of drying the prepared ZTC.
  8. 8 . The method of claim 1 , wherein the prepared ZTC defines micropores in the range of 1.5 to 2 nm and mesopores in the range of 2 to 5 nm.
  9. 9 . The method of claim 1 , wherein the elevated temperature is in the range of 800 K to 1080 K.
  10. 10 . A supercapacitor comprising: an electrode, the electrode comprising an active material and a metallic component, wherein the active material comprises a zeolite-templated (ZTC) generated by the method of claim 1 ; an electrolyte comprising H 2 SO 4 ; and g membrane separator.
  11. 11 . The supercapacitor of claim 10 , wherein the supercapacitor retains a maximum of 75% of capacitance at high current densities of 15 A/g.
  12. 12 . The supercapacitor of claim 10 , wherein the ZTC has a surface area in the range of 2500 m 2 /g to 3000 m 2 /g.
  13. 13 . The supercapacitor of claim 10 , wherein the ZTC has a micropore density of greater than 1.0 cm 3 /g.
  14. 14 . The supercapacitor of claim 10 , wherein the supercapacitor has a capacitance is in the range of 100 to 250 F/g.
  15. 15 . A method for generating a zeolite-templated carbon (ZTC) for use as an active material in an electrode in a supercapacitor, the method comprising the steps of: providing a NaX zeolite; initiating ion exchange with the NaX zeolite and Ca +2 ions to generate a large crystalline calcium (LCaX) zeolite; performing carbon vapor deposition on the LCaX zeolite in a plug-flow reactor using acetylene to generate a ZTC-zeolite composition, wherein the carbon vapor deposition occurs at an elevated temperature; heating the ZTC by introducing an inert gas stream for a defined period of time, wherein the ZTC is heated to a graphitizing temperature in the range of 820 K to 1180 K, generating a graphitized ZTC-zeolite composition; cooling the graphitized ZTC-zeolite composition; and washing the graphitized ZTC-zeolite composition with acid, generating a prepared ZTC, the prepared ZTC having a select surface area and operable for use as an active material in an electrode in a supercapacitor.
  16. 16 . The method of claim 15 , wherein the inert gas stream comprises helium.
  17. 17 . The method of claim 15 , wherein the elevated temperature is in the range of 820 K to 873 K.
  18. 18 . The method of claim 15 , further comprising the steps of: Performing a second carbon vapor deposition on the graphitized ZTC-zeolite composition using acetylene, wherein the second carbon vapor deposition is performed at the elevated temperature.
  19. 19 . The method of claim 15 , wherein the elevated temperature is in the range of 800 K to 873 K.
  20. 20 . The method of claim 15 , wherein the acid is selected from the group consisting of: HCl, HF, and combinations of the same.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit and priority of PCT/IB2022/059432 filed on Oct. 3, 2022, and titled “USE OF ZEOLITE-TEMPLATED CARBON (ZTCS) AS ELECTRODES FOR SUPERCAPACITORS”. For purposes of United States patent practice, this application incorporates the contents of the International Application by reference in its entirety. FIELD This disclosure relates to zeolite-templated carbon (ZTC) usage. Specifically, disclosed herein are electrodes for supercapacitors generated from ZTCs and the methods used to generate the ZTCs. BACKGROUND Supercapacitors are electrochemical capacitors that store electrical energy. Supercapacitors have a lower weight, a faster discharge, faster charging, a longer lifetime of charge cycles, and excellent temperature performance in comparison with traditional battery or conventional capacitors. Performance of supercapacitors are related to several factors, including electrolyte selection and electrode material makeup. Capacitance is proportional to the surface area of the electrodes; thus, electrochemical inert materials with high specific surface areas are utilized. Conventional electrode materials include activated carbon, metal oxides, or graphite. Conventional electrode materials lack uniform pores and channels, or have “dead pores” that prevent ion exchange. Additionally, traditional materials can be difficult to produce consistently in large batches, and have inconsistent manufacturing results. Therefore, a need exists for a material for use as supercapacitor electrodes with a high capacitance and a large surface area. SUMMARY OF THE INVENTION Disclosed herein is a method for generating a zeolite-templated carbon (ZTC) for use as an active material in an electrode in a supercapacitor. The method includes the steps of providing a CaX zeolite at a select size, and performing carbon vapor deposition on the CaX zeolite in a plug-flow reactor using an organic precursor to generate a ZTC-zeolite composition. The carbon vapor deposition occurs at an elevated temperature. The method also includes the states of cooling the ZTC-zeolite composition; heating the ZTC-zeolite composition by introducing an inert gas stream for a defined period of time, and where the ZTC is heated to a graphitizing temperature in the range of 820 K to 1180 K, to generate a graphitized ZTC-zeolite composition; cooling the graphitized ZTC-zeolite composition; and washing the graphitized ZTC-zeolite composition with acid to generate a prepared ZTC. The prepared ZTC is operable for use as an active material in an electrode in a supercapacitor and has a select surface area. In some embodiments, the inert gas stream is a helium stream containing helium. In some embodiments, the inert gas stream is a nitrogen stream containing nitrogen. The inert gas stream is heated. In some embodiments, the organic precursor is selected from the group including propylene, ethanol, acetylene, and combinations of the same. In other embodiments, the organic precursor includes propylene. In some embodiments, the acid is selected from the group including HCl, HF, and combinations of the same. The method also includes the step of drying the prepared ZTC. In some embodiments, the prepared ZTC defines micropores in the range of 1.5 to 2 nm and mesopores in the range of 2 to 5 nm. The elevated temperature is in the range of 800 K to 1080 K. Further disclosed herein is a supercapacitor including an electrode, where the electrode includes an active material and a metallic component. The active material includes a zeolite-templated carbon (ZTC) generated by the methods claimed herein. The supercapacitor also includes an electrolyte solution including H2SO4 and a membrane separator. In some embodiments, the supercapacitor retains a maximum of 75% of capacitance at high current densities of 15 A/g. In some embodiments, the ZTC has a surface area in the range of 2500 m2/g to 3000 m2/g. In some embodiments, the ZTC has a micropore density of greater than 1.0 cm3/g. In some embodiments, the supercapacitor has a capacitance is in the range of 100 to 250 F/g. Further disclosed herein is a method for generating a zeolite-templated carbon (ZTC) for use as an active material in an electrode in a supercapacitor. The method includes the steps of providing a NaX zeolite; initiating ion exchange with the NaX zeolite and Ca+2 ions to generate a large crystalline calcium (LCaX) zeolite; and performing carbon vapor deposition on the LCaX zeolite in a plug-flow reactor using acetylene to generate a ZTC-zeolite composition. The carbon vapor deposition occurs at an elevated temperature. The method also includes the states of cooling the ZTC-zeolite composition; heating the ZTC-zeolite composition by introducing an inert gas stream for a defined period of time, where the ZTC is heated to a graphitizing temperature in the range of 820 K to 1180 K, to generate a graphitized ZTC-zeolite composition; cooling the graphitize