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Transforming CO2 into advanced 3D printed carbon nanocomposites

Author

Listed:
  • Bradie S. Crandall

    (Washington University
    Washington University
    University of Delaware)

  • Matthew Naughton

    (University of Delaware)

  • Soyeon Park

    (University of Delaware)

  • Jia Yu

    (Washington University
    Washington University)

  • Chunyan Zhang

    (University of Delaware
    University of Delaware)

  • Shima Mahtabian

    (University of Delaware)

  • Kaiying Wang

    (Washington University)

  • Xinhua Liang

    (Washington University)

  • Kelvin Fu

    (University of Delaware
    University of Delaware)

  • Feng Jiao

    (Washington University
    Washington University)

Abstract

The conversion of CO2 emissions into valuable 3D printed carbon-based materials offers a transformative strategy for climate mitigation and resource utilization. Here, we 3D print carbon nanocomposites from CO2 using an integrated system that electrochemically converts CO2 into CO, followed by a thermocatalytic process that synthesizes carbon nanotubes (CNTs) which are then 3D printed into high-density carbon nanocomposites. A 200 cm2 electrolyzer stack is integrated with a thermochemical reactor for more than 45 h of operation, cumulatively synthesizing 37 grams of CNTs from CO2. A techno-economic analysis indicates a 90% cost reduction in CNT production on an industrial scale compared to current benchmarks, underscoring the commercial viability of the system. A 3D printing process is developed that achieves a high nanocomposite CNT concentration (38 wt%) while enhancing composite structural attributes via CNT alignment. With the rapidly rising demand for carbon nanocomposites, this CO2-to-nanocomposite process can make a substantial impact on global carbon emission reduction efforts.

Suggested Citation

  • Bradie S. Crandall & Matthew Naughton & Soyeon Park & Jia Yu & Chunyan Zhang & Shima Mahtabian & Kaiying Wang & Xinhua Liang & Kelvin Fu & Feng Jiao, 2024. "Transforming CO2 into advanced 3D printed carbon nanocomposites," Nature Communications, Nature, vol. 15(1), pages 1-9, December.
    • Handle: RePEc:nat:natcom:v:15:y:2024:i:1:d:10.1038_s41467-024-54957-w
    DOI: 10.1038/s41467-024-54957-w
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    References listed on IDEAS

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    2. Haeun Shin & Kentaro U. Hansen & Feng Jiao, 2021. "Techno-economic assessment of low-temperature carbon dioxide electrolysis," Nature Sustainability, Nature, vol. 4(10), pages 911-919, October.
    3. Cameron Hepburn & Ella Adlen & John Beddington & Emily A. Carter & Sabine Fuss & Niall Mac Dowell & Jan C. Minx & Pete Smith & Charlotte K. Williams, 2019. "The technological and economic prospects for CO2 utilization and removal," Nature, Nature, vol. 575(7781), pages 87-97, November.
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