Pyrolytic carbon black composite and method of making the same

1. A method of recovering carbon black, comprising the steps of:

providing a carbonaceous source material containing carbon black;

contacting the carbonaceous source material with a sulfonation bath to produce a sulfonated material, wherein the sulfonation bath comprises sulfonation agent is chlorosulfonic acid in 1,2 dichloroethane solution; and,

pyrolyzing the sulfonated material to produce a carbon black containing product comprising a glassy carbon matrix phase having carbon black dispersed therein.

2. The method of claim 1 , wherein the sulfonation bath is an oleum bath.

3. The method of claim 1 , wherein the sulfonation bath comprises between 0.1-65 wt. % SO 3 .

4. The method of claim 1 , wherein pyrolysis step is conducted at a temperature that is greater than 1000° C.

5. The method of claim 1 , wherein pyrolysis step is conducted at a temperature that is between 200-1000° C.

6. The method of claim 1 , further comprising the steps of reducing the carbonaceous source material to a powder prior to contacting the carbonaceous source material with the oleum bath.

7. The method of claim 6 , wherein the powder has an average maximum dimension of less than 100 nm to 10 cm.

8. The method of claim 1 , wherein the carbonaceous source material comprises carbon reinforced composites.

9. The method of claim 8 , wherein the carbon reinforcing agent is at least one selected from the group consisting of carbon black, carbon particles, nanoparticles, mesoparticles and fibers.

10. The method of claim 1 , wherein the carbonaceous source material is a waste material.

11. The method of claim 10 , wherein the waste material is rubber tires.

12. The method of claim 1 , wherein the carbon black containing product has a specific surface area of less than 1000 m 2 /g.

13. The method of claim 1 , wherein the pyrolyzing step occurs after the contacting step.

14. The method of claim 1 , wherein the pyrolyzing step occurs before the contacting step.

15. A method of recovering carbon black, comprising the steps of:

providing a carbonaceous source material containing carbon black;

contacting the carbonaceous source material with a sulfonation bath to produce a sulfonated material,

pyrolyzing the sulfonated material to produce a carbon black containing product comprising a glassy carbon matrix phase having carbon black dispersed therein; and

wherein the carbon black product has an average pore size of less than 8 nm.

16. The method of claim 15 , wherein the sulfonation bath is an oleum bath.

17. The method of claim 15 , wherein the sulfonation bath comprises between 0.1-65 wt. % SO 3 .

18. The method of claim 15 , wherein pyrolysis step is conducted at a temperature that is greater than 1000° C.

19. The method of claim 15 , wherein pyrolysis step is conducted at a temperature that is between 200-1000° C.

20. The method of claim 15 , further comprising the steps of reducing the carbonaceous source material to a powder prior to contacting the carbonaceous source material with the oleum bath.

21. The method of claim 20 , wherein the powder has an average maximum dimension of less than 100 nm to 10 cm.

22. The method of claim 15 , wherein the carbonaceous source material comprises carbon reinforced composites.

23. The method of claim 22 , wherein the carbon reinforcing agent is at least one selected from the group consisting of carbon black, carbon particles, nanoparticles, mesoparticles and fibers.

24. The method of claim 15 , wherein the carbonaceous source material is a waste material.

25. The method of claim 24 , wherein the waste material is rubber tires.

26. The method of claim 15 , wherein the carbon black containing product has a specific surface area of less than 1000 m 2 /g.

27. The method of claim 15 , wherein the pyrolyzing step occurs after the contacting step.

28. The method of claim 15 , wherein the pyrolyzing step occurs before the contacting step.

29. A method of recovering carbon black, comprising the steps of:

providing a carbonaceous source material containing carbon black;

contacting the carbonaceous source material with a sulfonation bath to produce a sulfonated material,

pyrolyzing the sulfonated material to produce a carbon black containing product comprising a glassy carbon matrix phase having carbon black dispersed therein; and

wherein the carbon black product has an average pore size of between 2 and 120 nm.

30. The method of claim 29 , wherein the sulfonation bath is an oleum bath.

31. The method of claim 29 , wherein the sulfonation bath comprises between 0.1-65 wt. % SO 3 .

32. The method of claim 29 , wherein pyrolysis step is conducted at a temperature that is greater than 1000° C.

33. The method of claim 29 , wherein pyrolysis step is conducted at a temperature that is between 200-1000° C.

34. The method of claim 29 , further comprising the steps of reducing the carbonaceous source material to a powder prior to contacting the carbonaceous source material with the oleum bath.

35. The method of claim 34 , wherein the powder has an average maximum dimension of less than 100 nm to 10 cm.

36. The method of claim 29 , wherein the carbonaceous source material comprises carbon reinforced composites.

37. The method of claim 36 , wherein the carbon reinforcing agent is at least one selected from the group consisting of carbon black, carbon particles, nanoparticles, mesoparticles and fibers.

38. The method of claim 29 , wherein the carbonaceous source material is a waste material.

39. The method of claim 38 , wherein the waste material is rubber tires.

40. The method of claim 29 , wherein the carbon black containing product has a specific surface area of less than 1000 m 2 /g.

41. The method of claim 29 , wherein the pyrolyzing step occurs after the contacting step.

42. The method of claim 29 , wherein the pyrolyzing step occurs before the contacting step.

43. A method of recovering carbon black, comprising the steps of:

providing a carbonaceous source material containing carbon black;

contacting the carbonaceous source material with a sulfonation bath to produce a sulfonated material,

pyrolyzing the sulfonated material to produce a carbon black containing product comprising a glassy carbon matrix phase having carbon black dispersed therein; and

wherein the carbon black product is further surface activated and the carbon black product has an average pore size between 1 and 20 nm and a density of pores having an average pore size between 1 and 20 nm is increased.

44. The method of claim 43 , wherein the sulfonation bath is an oleum bath.

45. The method of claim 43 , wherein the sulfonation bath comprises between 0.1-65 wt. % SO 3 .

46. The method of claim 43 , wherein pyrolysis step is conducted at a temperature that is greater than 1000° C.

47. The method of claim 43 , wherein pyrolysis step is conducted at a temperature that is between 200-1000° C.

48. The method of claim 43 , further comprising the steps of reducing the carbonaceous source material to a powder prior to contacting the carbonaceous source material with the oleum bath.

49. The method of claim 48 , wherein the powder has an average maximum dimension of less than 100 nm to 10 cm.

50. The method of claim 43 , wherein the carbonaceous source material comprises carbon reinforced composites.

51. The method of claim 50 , wherein the carbon reinforcing agent is at least one selected from the group consisting of carbon black, carbon particles, nanoparticles, mesoparticles and fibers.

52. The method of claim 43 , wherein the carbonaceous source material is a waste material.

53. The method of claim 52 , wherein the waste material is rubber tires.

54. The method of claim 43 , wherein the carbon black containing product has a specific surface area of less than 1000 m 2 /g.

55. The method of claim 43 , wherein the pyrolyzing step occurs after the contacting step.

56. The method of claim 43 , wherein the pyrolyzing step occurs before the contacting step.

57. A method of recovering carbon black, comprising the steps of:

providing a carbonaceous source material containing carbon black;

contacting the carbonaceous source material with a sulfonation bath to produce a sulfonated material,

pyrolyzing the sulfonated material to produce a carbon black containing product comprising a glassy carbon matrix phase having carbon black dispersed therein; and

wherein the carbon black containing product has a specific surface area of less than 100 m 2 /g.

58. The method of claim 57 , wherein the sulfonation bath is an oleum bath.

59. The method of claim 57 , wherein the sulfonation bath comprises between 0.1-65 wt. % SO 3 .

60. The method of claim 57 , wherein pyrolysis step is conducted at a temperature that is greater than 1000° C.

61. The method of claim 57 , wherein pyrolysis step is conducted at a temperature that is between 200-1000° C.

62. The method of claim 57 , further comprising the steps of reducing the carbonaceous source material to a powder prior to contacting the carbonaceous source material with the oleum bath.

63. The method of claim 62 , wherein the powder has an average maximum dimension of less than 100 nm to 10 cm.

64. The method of claim 57 , wherein the carbonaceous source material comprises carbon reinforced composites.

65. The method of claim 64 , wherein the carbon reinforcing agent is at least one selected from the group consisting of carbon black, carbon particles, nanoparticles, mesoparticles and fibers.

66. The method of claim 57 , wherein the carbonaceous source material is a waste material.

67. The method of claim 66 , wherein the waste material is rubber tires.

68. The method of claim 57 , wherein the pyrolyzing step occurs after the contacting step.

69. The method of claim 57 , wherein the pyrolyzing step occurs before the contacting step.

70. A method of making a battery electrode comprising carbon black, the method comprising the steps of:

providing a carbonaceous source material containing carbon black;

contacting the carbonaceous source material with an oleum sulfonation bath to produce a sulfonated material;

wherein the sulfonation bath comprises sulfonation agent is chlorosulfonic acid in 1,2 dichloroethane solution; and,

pyrolyzing the sulfonated material to produce a carbon black product comprising a glassy carbon matrix phase having carbon black dispersed therein; and,

forming a battery electrode from the carbon black containing product.

71. The method of claim 70 , wherein the battery electrode is an anode.

72. The method of claim 71 , wherein the battery is a lithium ion or a sodium ion battery.

73. The method of claim 70 , wherein the battery is a lithium ion battery or a sodium ion battery.

74. A method of making a battery electrode comprising carbon black, the method comprising the steps of:

providing a carbonaceous source material containing carbon black;

contacting the carbonaceous source material with an oleum bath to produce a sulfonated material;

pyrolyzing the sulfonated material to produce a carbon black product comprising a glassy carbon matrix phase having carbon black dispersed therein;

wherein the carbon black product has an average pore size that is less than 8 nm; and,

forming a battery electrode from the carbon black containing product.

75. The method of claim 74 , wherein the battery electrode is an anode.

76. The method of claim 75 , wherein the battery is a lithium ion or a sodium ion battery.

77. The method of claim 74 , wherein the battery is a lithium ion battery or a sodium ion battery.

78. A method of making a battery electrode comprising carbon black, the method comprising the steps of:

providing a carbonaceous source material containing carbon black;

contacting the carbonaceous source material with an oleum bath to produce a sulfonated material;

pyrolyzing the sulfonated material to produce a carbon black product comprising a glassy carbon matrix phase having carbon black dispersed therein;

wherein the carbon black product has an average pore size that is between 2 and 120 nm; and

forming a battery electrode from the carbon black containing product.

79. The method of claim 78 , wherein the battery electrode is an anode.

80. The method of claim 79 , wherein the battery is a lithium ion or a sodium ion battery.

81. The method of claim 78 , wherein the battery is a lithium ion battery or a sodium ion battery.

82. A method of making a battery electrode comprising carbon black, the method comprising the steps of:

providing a carbonaceous source material containing carbon black;

contacting the carbonaceous source material with an oleum bath to produce a sulfonated material;

pyrolyzing the sulfonated material to produce a carbon black product comprising a glassy carbon matrix phase having carbon black dispersed therein;

wherein the carbon black product is further surface activated and the carbon black product has an average pore size between 1 and 20 nm and a density of the pores having an average pore size between 1 and 20 nm is increased; and,

forming a battery electrode from the carbon black containing product.

83. The method of claim 82 , wherein the battery electrode is an anode.

84. The method of claim 83 , wherein the battery is a lithium ion or a sodium ion battery.

85. The method of claim 82 , wherein the battery is a lithium ion battery or a sodium ion battery.

86. A method of making a battery electrode comprising carbon black, the method comprising the steps of:

providing a carbonaceous source material containing carbon black;

contacting the carbonaceous source material with an oleum bath to produce a sulfonated material;

pyrolyzing the sulfonated material to produce a carbon black product comprising a glassy carbon matrix phase having carbon black dispersed therein;

wherein the carbon black containing product has a specific surface area of less than 100 m 2 /g; and,

forming a battery electrode from the carbon black containing product.

87. The method of claim 86 , wherein the battery electrode is an anode.

88. The method of claim 87 , wherein the battery is a lithium ion or a sodium ion battery.

89. The method of claim 86 , wherein the battery is a lithium ion battery or a sodium ion battery.