Transforming CO2 into advanced 3D printed carbon nanocomposites
Bradie S. Crandall, Matt S. Naughton, Soyeon Park, Jia Yu, Chunyan Zhang, Shima Mahtabian, Kaiying Wang, Xinhua Liang, Kun Fu, Feng Jiao
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. This work develops a method to sequester carbon emissions into valuable 3D printed materials. By combining a reactor cascade with advanced additive manufacturing, this system offers the ability for carbon utilization at scale, a crucial step for addressing climate change.