Consolidated amorphous carbon materials, their manufacture and use

Abstract

A carbon based material produced from the consolidation of amorphous carbon by elevated temperature compression. The material having unique chemical and physical characteristics that lend themselves to a broad range of applications such as in electrical, electrochemical and structural fields.

1 . An electrode formed of a processed carbon material comprising amorphous carbon that has been consolidated under elevated temperature and pressure, wherein the temperature is less than 1000° C., and wherein the processed carbon material has a surface area of over 800 m 2 /g. 
     
     
         2 . The electrode set forth in  claim 1 , wherein processed carbon material has been consolidated with a temperature in the range of at least about 600° C. 
     
     
         3 . The electrode set forth in  claim 1 , wherein the processed carbon material has been consolidated with a pressure in the range of about 500-20,000 psi. 
     
     
         4 . The electrode set forth in  claim 1 , wherein the processed carbon material has been consolidated under elevated temperature and pressure for a holding time in the range of about 0.5-10 hours. 
     
     
         5 . The electrode set forth in  claim 1 , wherein the processed carbon material has a surface area of over 931 m 2 /q. 
     
     
         6 . The electrode set forth in  claim 1 , wherein the processed carbon material has an electrical resistivity in the range of 0.040-0.150 Ω·cm. 
     
     
         7 . The electrode set forth in  claim 1 , wherein the processed carbon material has a porosity in the range of 12-31%. 
     
     
         8 . The electrode set forth in  claim 1 , wherein the electrode is used in at least one of the following applications: an ultracapacitor, a water treatment system, an electroplating circuit, a desalination cell, a metal concentration system, a waste treatment system, a solid-liquid separation system, a battery, a fuel cell, and combinations thereof. 
     
     
         9 . A method for performing electrochemistry, the method comprising:
 providing a first electrode comprising activated amorphous carbon consolidated under elevated temperature and pressure;   placing the first electrode in fluid communication with a liquid comprising at least one of an electrolyte solution or a slurry; and   applying a potential difference between the first electrode and a reference electrode.   
     
     
         10 . The method set forth in  claim 9 , wherein the first electrode is formed by consolidating activated amorphous carbon at temperature of less than 1000° C. 
     
     
         11 . The method set forth in  claim 9 , wherein the reference electrode includes a second electrode comprising activated amorphous carbon consolidated under elevated temperature and pressure. 
     
     
         12 . The method set forth in  claim 9 , wherein the liquid comprises an electrolyte solution, and further comprising removing ions from the electrolyte solution by forming an electrical double layer between the electrolyte solution and the first electrode. 
     
     
         13 . The method set forth in  claim 12 , further comprising
 grounding the first electrode to discharge the ions from the first electrode;   reapplying a potential difference between the first electrode and a reference electrode to reuse the first electrode to perform electrochemistry.   
     
     
         14 . The method set forth in  claim 12 , wherein removing ions from the electrolyte solution includes removing at least one of metal ions and salt ions. 
     
     
         15 . The method set forth in  claim 12 , wherein removing ions from the electrolyte solution includes removing ions to perform at least one of the following functions: desalinating water, deionizing water, concentrating metal ions, and removing pollutants from at least one of a waste stream and water. 
     
     
         16 . The method set forth in  claim 9 , wherein applying a potential difference between the first electrode and a reference electrode includes establishing a charge separation between the first electrode and the electrolyte solution to form an ultracapacitor. 
     
     
         17 . The method set forth in  claim 9 , wherein applying a potential difference between the first electrode and a reference electrode includes establishing an electroplating circuit. 
     
     
         18 . The method set forth in  claim 9 , wherein the liquid comprises a slurry having charged particles, and further comprising attracting the charged particles to at least one of the first electrode and the reference electrode. 
     
     
         19 . A process for the production of an electrode formed of consolidated amorphous carbon, the process comprising:
 consolidating amorphous carbon using elevated temperature and pressure, wherein the consolidating is performed at a temperature of less than 1000° C.   
     
     
         20 . The process set forth in  claim 19 , wherein the consolidating is performed at a temperature in the range of 600-1000° C. 
     
     
         21 . The process set forth in  claim 19 , wherein the consolidating is performed at a pressure in the range of 500-20,000 psi. 
     
     
         22 . The process set forth in  claim 19 , wherein the electrode has a surface area of at least 800 m 2 /g. 
     
     
         23 . The process set forth in  claim 19 , wherein the electrode has a porosity of at least 12%. 
     
     
         24 . The process set forth in  claim 19 , wherein the electrode has a resistivity in the range of 0.040-0.150Ω·cm. 
     
     
         25 . The process set forth in  claim 19 , wherein the electrode is used in at least one of the following applications: storing electrical energy, desalinating water, deionizing water, recovering metal ions, removing solid particles from a slurry, removing pollutants from at least one of a waste stream and water, electroplating metal ions, and combinations thereof. 
     
     
         26 . The process set forth in  claim 19 , wherein the electrode is used in at least one of a battery and a fuel cell.