PHYSICAL SCIENCES INC. — Department of Energy SBIR Phase II: 18c

Description

Domestic coal can be used to manufacture high value carbon products. The market value of these high performance materials significantly exceeds the fuel and heat value of coal, which illustrates there are sustainable market forces for manufacturing carbon materials from coal. Current processes pose significant challenges associated with the substantial chemical modifications of the native coal structures that require high temperatures and/or strongly oxidative, highly corrosive reagents. General statement of how this problem is being addressed. An innovative approach for producing high value, carbonbased products from coal feedstocks for the manufacturing of high performance materials for electrochemical applications was proposed. The low environmental footprint process requires minimal reagent usage, efficient recycling >90% and produces a carbon product for electrochemical applications with >200X higher value than the coal price. In addition, the process generates valuable byproducts such as minerals and low emission gaseous fuels. What was done in Phase I and Phase II? In Phase I, the feasibility of the approach was successfully demonstrated. Domestic coal feedstocks were demonstrated in scalable processes to produce the high performance material, and battery electrodes for the next generation lithium ion batteries were produced. In the Phase II Base, production scale up of the target carbon product was demonstrated. The process production and performance was validated by a carbon manufacturer. Technoeconomic analysis demonstrated viability of the process. What is planned for the Phase II project? The proposed Phase IIA program will complete the scope of the Phase II Base and will provide enhanced objectives: a the scaleup of carbon production multikilogram scale; b demonstration of a product in battery electrode applications pouch cells; c extensive characterization of properties for additional target applications; d increased fidelity for the technoeconomic model that will be used for technology transition. Collaboration with a carbon manufacturer will develop a plan for profitable conversion of coal to high conductivity carbon on the multiton scale and enable the technology transition into Phase III commercial production. Commercial Applications and Other Benefits limited to the space provided. The proposed approach will demonstrate an economically viable process to produce high value, carbon materials from coal feedstocks. These materials will have a much higher market value than the fuel value of coal, and thus will provide a sustainable market for their manufacturing. In addition, the proposed process will generate valuable coproducts that can be integrated with other commercial operations such as the recovery of trace elements and lowemission energy production.