(512a) Efficient Process for the Production of High Conductivity, Carbon-Rich Materials from Coal

Abstract: Domestic coal can be used to manufacture high value carbon products for multiple applications. The market value of these high performance materials often exceeds the fuel and heat value of coal, which illustrates there are sustainable market forces for manufacturing carbon materials from coal. Current processes to produce high performance carbon materials from coal pose significant challenges due to the high temperatures and corrosive reagents required to substantially modify the native coal structures. Under a Department of Energy sponsored program, Physical Sciences Inc. (PSI) developed and demonstrated an innovative approach for producing high value, carbon-based products from coal feedstocks for electrochemical applications. The key innovation is a two‑step process that generates both a high conductivity carbon material (HCCM) and valuable byproducts (mineral fractions for trace elements recovery and low emission fuels). PSI demonstrated: (1) a highly robust and scalable processes (multi-grams to kilograms) to produce the target carbon product with appropriate surface area (>50 m²/g) and low mineral content (Fe<100 ppm); (2) comparable electrochemical performance of PSI’s coal-derived HCCM in battery electrodes compared to a benchmark commercial product; and (3) economic feasibility for scale-up and commercialization. This presentation will provide a comprehensive overview of the overall process that provides economical production of high conductivity carbon materials for electrochemical applications. In addition, the technical approach, key results including detailed analysis, conclusions, and the next steps will be discussed in this presentation.

Acknowledgement: This material is based upon work supported by the U.S. Department of Energy, Office of Science, Office of Chicago Ops, under Award Number(s) DE-SC0018837.

Disclaimer: This paper was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof.

20 YEAR SBIR/STTR DATA RIGHTS (2019)

Funding Agreement No. DE SC00018837

Award Date: 8/19/19

SBIR/STTR Protection Period: 8/19/39

SBIR/STTR Awardee: Physical Sciences Inc., 20 New England Business Center, Andover, MA 01810

This report contains SBIR/STTR Data to which the Federal Government has received SBIR/STTR Technical Data Rights or SBIR/STTR Computer Software Rights during the SBIR/STTR Protection Period and Unlimited Rights afterwards, as defined in the Funding Agreement. Any reproductions of SBIR/STTR Data must include this legend.