A Data-Driven Approach to Molten Salt Synthesis of N-Rich Carbon Adsorbents for Selective CO2 Capture

Applying a design of experiments methodology to the molten salt synthesis of nanoporous carbons enables inverse design and optimization of nitrogen (N)-rich carbon adsorbents with excellent CO2 /N2 selectivity and appreciable CO2 capacity for carbon capture via swing adsorption from dilute gas mixtures such as natural gas combined cycle flue gas. This data-driven study reveals fundamental structure-function relationships between the synthesis conditions, physicochemical properties, and achievable selective adsorption performance of N-rich nanoporous carbons derived from molten salt synthesis for CO2 capture. Taking advantage of size-sieving separation of CO2 (3.30 Å) from N2 (3.64 Å) within the turbostratic nanostructure of these N-rich carbons, while limiting deleterious N2 adsorption in a weaker adsorption site that harms selectivity, enables a large CO2 capacity (0.73 mmol g-1 at 30.4 Torr and 30 °C) with noteworthy concurrent CO2 /N2 selectivity as predicted by the ideal adsorbed solution theory (SIAST = 246) with an adsorbed phase purity of 91% from a simulated gas stream containing only 4% CO2 . Optimized N-rich porous carbons, with good physicochemical stability, low cost, and moderate regeneration energy, can achieve performance for selective CO2 adsorption that competes with other classes of advanced porous materials such as chemisorbing zeolites and functionalized metal-organic frameworks.

Molten Salts Approach of Poly(vinyl alcohol)-Derived Bimetallic Nickel-Iron Sheets Supported on Porous Carbon Nanosheet as an Effective and Durable Electrocatalyst for Methanol Oxidation

The preparation of metallic nanostructures supported on porous carbon materials that are facile, green, efficient, and low-cost is desirable to reduce the cost of electrocatalysts, as well as reduce environmental pollutants. In this study, a series of bimetallic nickel-iron sheets supported on porous carbon nanosheet (NiFe@PCNs) electrocatalysts were synthesized by molten salt synthesis without using any organic solvent or surfactant through controlled metal precursors. The as-prepared NiFe@PCNs were characterized by scanning and transmission electron microscopy (SEM and TEM), X-ray diffraction, and photoelectron spectroscopy (XRD and XPS). The TEM results indicated the growth of NiFe sheets on porous carbon nanosheets. The XRD analysis confirmed that the Ni_1-xFe_x alloy had a face-centered polycrystalline (fcc) structure with particle sizes ranging from 15.5 to 30.6 nm. The electrochemical tests showed that the catalytic activity and stability were highly dependent on the iron content. The electrocatalytic activity of catalysts for methanol oxidation demonstrated a nonlinear relationship with the iron ratio. The catalyst doped with 10% iron showed a higher activity compared to the pure nickel catalyst. The maximum current density of Ni_0.9Fe_0.1@PCNs (Ni/Fe ratio 9:1) was 190 mA/cm² at 1.0 M of methanol. In addition to the high electroactivity, the Ni_0.9Fe_0.1@PCNs showed great improvement in stability over 1000 s at 0.5 V with a retained activity of 97%. This method can be used to prepare various bimetallic sheets supported on porous carbon nanosheet electrocatalysts.

An Effective Electrochemical Platform for Chloramphenicol Detection Based on Carbon-Doped Boron Nitride Nanosheets

Currently, accurate quantification of antibiotics is a prerequisite for health care and environmental governance. The present work demonstrated a novel and effective electrochemical strategy for chloramphenicol (CAP) detection using carbon-doped hexagonal boron nitride (C-BN) as the sensing medium. The C-BN nanosheets were synthesized by a molten-salt method and fully characterized using various techniques. The electrochemical performances of C-BN nanosheets were studied using cyclic voltammetry (CV) and electrochemical impedance spectroscopy (EIS). The results showed that the electrocatalytic activity of h-BN was significantly enhanced by carbon doping. Carbon doping can provide abundant active sites and improve electrical conductivity. Therefore, a C-BN-modified glassy carbon electrode (C-BN/GCE) was employed to determine CAP by differential pulse voltammetry (DPV). The sensor showed convincing analytical performance, such as a wide concentration range (0.1 µM-200 µM, 200 µM-700 µM) and low limit of detection (LOD, 0.035 µM). In addition, the proposed method had high selectivity and desired stability, and can be applied for CAP detection in actual samples. It is believed that defect-engineered h-BN nanomaterials possess a wide range of applications in electrochemical sensors.

Molten Salt Synthesis of Intermetallic Compound TiNi Nanopowder Passivated by TiOx Shell Prepared from NiTiO3 for Catalytic Hydrogenation

Titanium-nickel alloy is an attractive material due to its unique properties of shape memory effect, superior elasticity, and biocompatibility. Generally, Ti-Ni alloy powders are prepared from pure elemental powders of Ti and Ni as starting materials, but it is an energy-intensive process to obtain pure titanium. In this study, intermetallic compound TiNi powder passivated by TiO_x shell was prepared by directly reducing a commercial NiTiO₃ using CaH₂ reducing agent in a molten LiCl at 650 °C. Analyses by X-ray diffraction, scanning electron microscopy/transmission electron microscopy with energy-dispersive X-ray spectroscopy and X-ray photoelectron spectroscopy revealed that the powder had a core-shell structure, with the core of TiNi and the shell of TiO_x-rich composition with scarce metallic Ni nicely catalyzing hydrogenation reactions with good recyclability and stability.

Molten Salt Shielded Synthesis of Monodisperse Layered CaZnOS-Based Semiconductors for Piezophotonic and X-Ray Detection Applications

CaZnOS-based semiconductors are the only series of material system discovered that can simultaneously realize a large number of dopant elements to directly fulfill the highly efficient full-spectrum functionality from ultraviolet to near-infrared under the same force/pressure. Nevertheless, owing to the high agglomeration of the high temperature solid phase manufacturing process, which is unable to control the crystal morphology, the application progress is limited. Here, the authors report first that CaZnOS-based fine monodisperse semiconductor crystals with various doping ions are successfully synthesized by a molten salt shielded method in an air environment. This method does not require inert gas ventilation, and therefore can greatly reduce the synthesis cost and more importantly improve the fine control of the crystal morphology, along with the crystals' dispersibility and stability. These doped semiconductors can not only realize different colors of mechanical-to-optical energy conversion, but also can achieve multicolor luminescence under low-dose X-ray irradiation, moreover their intensities are comparable to the commercial NaI:Tl. They can pave the way to the new fields of advanced optoelectronic applications, such as piezophotonic systems, mechanical energy conversion and harvesting devices, intelligent sensors, and artificial skin as well as X-ray applications.

One-Pot Synthesis of Alumina-Titanium Diboride Composite Powder at Low Temperature

Alumina-titanium diboride (Al₂O₃-TiB₂) composite powders were synthesised via aluminothermic reduction of TiO₂ and B₂O₃, mediated by a molten chloride salt (NaCl, KCl, or MgCl₂). The effects of salt type, initial batch composition, and firing temperature/time on the phase formation and overall reaction extent were examined. Based on the results and equilibrium thermodynamic calculations, the mechanisms underpinning the reaction/synthesis processes were clarified. Given their evaporation losses at test temperatures, appropriately excessive amounts of Al and B₂O₃ are needed to complete the synthesis reaction. Following this, phase-pure Al₂O₃-TiB₂ composite powders composed of 0.3-0.6 μm Al₂O₃ and 30-60 nm TiB₂ particles were successfully fabricated in NaCl after 5 h at 1050 °C. By increasing the firing temperature to 1150 °C, the time required to complete the synthesis reaction could be reduced to 4 h, although the sizes of Al₂O₃ and TiB₂ particles in the resultant phase pure composite powder increased slightly to 1-2 μm and 100-200 nm, respectively.

Scalable Synthesis of Tungsten Disulfide Nanosheets for Alkali-Acid Electrocatalytic Sulfion Recycling and H2 Generation

WS₂ nanosheets hold great promise for a variety of applications yet faces a grand challenge in terms of large-scale synthesis. We report a reliable, scalable, and high-yield (>93 %) synthetic strategy to fabricate WS₂ nanosheets, which exhibit highly desirable electrocatalytic properties toward both the alkaline sulfion (S^2- ) oxidation reaction (SOR) and the acidic hydrogen evolution reaction (HER). The findings prompted us to develop a hybrid alkali-acid electrochemical cell with the WS₂ nanosheets as bifunctional electrode catalysts of alkaline anodic SOR and acidic cathodic HER. The proof-of-concept device holds promise for self-power or low-electricity electrolytic H₂ generation and environmentally friendly recycling of sulfion with enhanced electron utilization efficiency.

Spontaneous formation of multilayer refractory carbide coatings in a molten salt media

Refractory materials hold great promise to develop functional multilayer coating for extreme environments and temperature applications but require high temperature and complex synthesis to overcome their strong atomic bonding and form a multilayer structure. Here, a spontaneous reaction producing sophisticated multilayer refractory carbide coatings on carbon fiber (CF) is reported. This approach utilizes a relatively low-temperature (950 °C) molten-salt process for forming refractory carbides. The reaction of titanium (Ti), chromium (Cr), and CF yields a complex, high-quality multilayer carbide coating composed of 1) Cr carbide (Cr₃C₂), 2) Ti carbide, and 3) Cr₃C₂ layers. The layered sequence arises from a difference in metal dissolutions, reactions, and diffusion rates in the salt media. The multilayer-coated CFs act as a permeable oxidation barrier with no crystalline degradation of the CFs after extreme temperature (1,200 °C) and environment (oxyacetylene flame) exposure. The synthesis of high-quality multilayer refractory coating in a fast, efficient, easy, and clean manner may answer the need for industrial applications that develop cheap and reliable extreme environment protection barriers.

Towards a Greener and Scalable Synthesis of Na2Ti6O13 Nanorods and Their Application as Anodes in Batteries for Grid-Level Energy Storage

Grid applications require high power density (for frequency regulation, load leveling, and renewable energy integration), achievable by combining multiple batteries in a system without strict high capacity requirements. For these applications however, safety, cost efficiency, and the lifespan of electrode materials are crucial. Titanates, safe and longevous anode materials providing much lower energy density than graphite, are excellent candidates for this application. The innovative molten salt synthesis approach proposed in this work provides exceptionally pure Na2Ti6O13 nanorods generated at 900-1100 °C in a yield ≥80 wt%. It is fast, cost-efficient, and suitable for industrial upscaling. Electrochemical tests reveal stable performance providing capacities of ≈100 mA h g-1 (Li) and 40 mA h g-1 (Na). Increasing the synthesis temperature to 1100 °C leads to a capacity decrease, most likely resulting from 1) the morphology/volume change with the synthesis temperature and 2) distortion of the Na2Ti6O13 tunnel structure indicated by electron energy-loss and Raman spectroscopy. The suitability of pristine Na2Ti6O13 as the anode for grid-level energy storage systems has been proven a priori, without any performance-boosting treatment, indicating considerable application potential especially due to the high yield and low cost of the synthesis route.

Highly Conductive Garnet-Type Electrolytes: Access to Li6.5La3Zr1.5Ta0.5O12 Prepared by Molten Salt and Solid-State Methods

Tantalum-doped garnet (Li_6.5La₃Zr_1.5Ta_0.5O₁₂, LLZTO) is a promising candidate to act as a solid electrolyte in all-solid-state batteries owing to both its high Li⁺ conductivity and its relatively high robustness against the Li metal. Synthesizing LLZTO using conventional solid-state reaction (SSR) requires, however, high calcination temperature (>1000 °C) and long milling steps, thereby increasing the processing time. Here, we report on a facile synthesis route to prepare LLZTO using a molten salt method (MSS) at lower reaction temperatures and shorter durations (900 °C, 5 h). Additionally, a thorough analysis on the properties, i.e., morphology, phase purity, and particle size distribution of the LLZTO powders, is presented. LLZTO pellets, either prepared by the MSS or the SSR method, that were sintered in a Pt crucible showed Li⁺ ion conductivities of up to 0.6 and 0.5 mS cm^-1, respectively. The corresponding activation energy values are 0.37 and 0.38 eV, respectively. The relative densities of the samples reached values of approximately 96%. For comparison, LLZTO pellets sintered in alumina crucibles or with γ-Al₂O₃ as sintering aid revealed lower ionic conductivities and relative densities with abnormal grain growth. We attribute these observations to the formation of Al-rich phases near the grain boundary regions and to a lower Li content in the final garnet phase. The MSS method seems to be a highly attractive and an alternative synthetic approach to SSR route for the preparation of highly conducting LLZTO-type ceramics.

Molten Salt Synthesis of High-Performance, Nanostructured La0.6Sr0.4FeO3-δ Oxygen Electrode of a Reversible Solid Oxide Cell

Nanoscale perovskite oxides with enhanced electrocatalytic activities have been widely used as oxygen electrodes of reversible solid oxide cells (RSOC). Here, La_0.6Sr_0.4FeO_3−δ (LSF) nanoscale powder is synthesized via a novel molten salt method using chlorides as the reaction medium and fired at 850 °C for 5 h after removing the additives. A direct assembly method is employed to fabricate the LSF electrode without a pre-sintering process at high temperature. The microstructure characterization ensures that the direct assembly process will not damage the porosity of LSF. When operating as a solid oxide fuel cell (SOFC), the LSF cell exhibits a peak power density of 1.36, 1.07 and 0.7 W/cm² at 800, 750 and 700 °C, respectively, while in solid oxide electrolysis cell (SOEC) mode, the electrolysis current density reaches 1.52, 0.98 and 0.53 A/cm² under an electrolysis voltage of 1.3 V, respectively. Thus, it indicates that the molten salt routine is a promising method for the synthesis of highly active perovskite LSF powders for directly assembled oxygen electrodes of RSOC.

Low Temperature Synthesis of Phase Pure MoAlB Powder in Molten NaCl

MoAlB fine powders were prepared in molten NaCl from Al, B and Mo powders. The effects of key parameters affecting the synthesis process and phase morphology were examined and the underpinning mechanisms proposed. MoAlB product particles exhibited different shapes/sizes, as follows: spherical grains (1~3 μm), plate-like particles (<5 μm in diameter) and columnar crystals with lengths up to 20 μm and diameters up to 5 μm, resultant from different reaction processes. Phase pure MoAlB was synthesised under the following optimal conditions: use of 140% excess Al and 6 h of firing at 1000 °C. This temperature was at least 100 °C lower than required by other methods/techniques previously reported. At the synthesis condition, Mo first reacted with Al and B, forming Al₈Mo₃ and MoB, respectively, which further reacted with excess Al to form Al-rich Al-Mo phases and MoAlB. The Al-rich Al-Mo phases further reacted with the residual B, forming additional MoAlB. The molten NaCl played an important role in accelerating the overall synthesis process.

Low-Temperature Molten Salt Synthesis and the Characterisation of Submicron-Sized Al8B4C7 Powder

Submicron-sized (~200 nm) aluminium boron carbide (Al₈B₄C₇) particles were synthesised from Al, B₄C and carbon black raw materials in a molten NaCl-based salt at a relatively low temperature. The effects of the salt type/assembly and the firing temperature on the synthesis process were examined, and the relevant reaction mechanisms discussed. The molten salt played an important role in the Al₈B₄C₇ formation process. By using a combined salt of 95%NaCl + 5%NaF, an effective liquid reaction medium was formed, greatly facilitating the Al₈B₄C₇ formation. As a result, essentially phase-pure Al₈B₄C₇ was obtained after 6 h of firing at 1250 °C. This temperature was 350–550 °C lower than that required by the conventional direct reaction and thermal reduction methods.

Synthesis of KCa₂Nb₃O₁₀ Crystals with Varying Grain Sizes and Their Nanosheet Monolayer Films As Seed Layers for PiezoMEMS Applications

The layered perovskite-type niobate KCa2Nb3O10 and its derivatives show advantages in several fields, such as templated film growth and (photo)catalysis. Conventional synthesis routes generally yield crystal size smaller than 2 μm. We report a flux synthesis method to obtain KCa2Nb3O10 crystals with significantly larger sizes. By using different flux materials (K2SO4 and K2MoO4), crystals with average sizes of 8 and 20 μm, respectively, were obtained. The KCa2Nb3O10 crystals from K2SO4 and K2MoO4 assisted synthesis were protonated and exfoliated into monolayer nanosheets, and the optimal exfoliation conditions were determined. Using pulsed laser deposition, highly (001)-oriented piezoelectric stacks (SrRuO3/PbZr0.52Ti0.48O3/SrRuO3, SRO/PZT/SRO) were deposited onto Langmuir-Blodgett films of Ca2Nb3O10(-) (CNO) nanosheets with varying lateral nanosheet sizes on Si substrates. The resulting PZT thin films showed high crystallinity irrespective of nanosheet size. The small sized nanosheets yielded a high longitudinal piezoelectric coefficient d33 of 100 pm/V, while the larger sized sheets had a d33 of 72 pm/V. An enhanced transverse piezoelectric coefficient d31 of -107 pm/V, an important input parameter for the actuation of active structures in microelectromechanical systems (MEMS) devices, was obtained for PZT films grown on CNO nanosheets with large lateral size, while the corresponding value on small sized sheets was -96 pm/V.

Morphologically controlled synthesis of porous spherical and cubic LaMnO3 with high activity for the catalytic removal of toluene

A morphology-controlled molten salt route was developed to synthesize porous spherical LaMnO3 and cubic LaMnO3 nanoparticles using the as-prepared porous Mn2O3 spheres as template. The porous LaMnO3 spheres with an average pore size of about 34.7 nm and the cubic LaMnO3 nanoparticles with a good dispersion were confirmed by scanning electron microscope, transmission electron microscope, and N2 adsorption-desorption measurements. The mechanism of morphological transformation from the porous spherical structure to the cubic particle in the molten salt was proposed. The porous spherical LaMnO3 and cubic LaMnO3 catalysts exhibited high catalytic performance for the combustion of toluene, and the latter performed better than the former. Under the conditions of toluene/oxygen molar ratio = 1/400 and space velocity = 20,000 h(-1), the temperature required for 10, 50, and 90% toluene conversion was 110, 170, and 220 °C over the cubic LaMnO3 catalyst, respectively. Based on the results of X-ray photoelectron spectroscopic and hydrogen temperature-programmed reduction characterization, we deduce that the higher surface Mn(4+)/Mn(3+) molar ratio and better low-temperature reducibility enhanced the catalytic performance of cubic LaMnO3. Taking the facile morphology-controlled synthesis and excellent catalytic performance into consideration, we believe that the well-defined morphological LaMnO3 samples are good candidate catalytic materials for the oxidative removal of toluene.