Claims:WE CLAIM:
1. A process for synthesizing a mesoporous carbon material using an industrial waste, comprising:
providing at least one of acid treatment, base treatment and effluent treatment to clean the industrial waste and to obtain dried powder;
removing iron from the dried powder to obtain a precursor composition, wherein the precursor composition comprises a copolymer and one or more carbon materials;
carbonizing the precursor composition, in an inert atmosphere, to obtain a partial mesoporous carbon material by pyrolysing the precursor composition at a carbonizing temperature for a predefined duration for converting the precursor composition to the partial mesoporous carbon material; and
processing the partial mesoporous carbon material to obtain the mesoporous carbon material.
2. The process as claimed in claim 1, wherein the industrial waste comprises waste from a forging industry.
3. The process as claimed in claim 1, wherein the removing the iron from the dried powder comprises
providing a magnetic field to the dried powder with a magnet capacity ranging from 700 to 1000 bars to obtain the precursor composition, and
wherein the magnetic field is configured to remove the iron at a flow rate of 50 to 100 kg/hr.
4. The process as claimed in claim 1, wherein the copolymer comprises at least one of anionic copolymer, cationic copolymer and neutral copolymer.
5. The process as claimed in claim 3, wherein the at least one of anionic copolymer, cationic copolymer and neutral copolymer being selected from a group comprising of Cetrimonium bromide (CTAB), Sodium Dodecyl Benzene Sulphonate (SDBS) and pluronic 123.
6. The process as claimed in claim 1, wherein the one or more carbon materials being selected from a group comprising of glucose, sucrose and fructose.
7. The process as claimed in claim 1, wherein the carbonizing of the precursor composition is carried in at least one of basic hydroxides medium, acidic medium and neutral medium.
8. The process as claimed in claim 1, wherein the inert atmosphere comprises at least one of N2 atmosphere, He atmosphere, Ar atmosphere and combination thereof.
9. The process as claimed in claim 1, processing the partial mesoporous carbon material to obtain the mesoporous carbon material comprises
providing at least one of acid treatment and base treatment to the partial mesoporous carbon material to maintain pH,
wherein the partial mesoporous carbon material, post the at least one of acid treatment and base treatment, being dried at 100°C;
treating a dried partial mesoporous carbon material with one or more phosphates and one or more aldehydes, and
wherein drying the partial mesoporous material treated with the one or more phosphates and the one or more aldehydes at temperature between 150?C to 250?C to obtain the mesoporous carbon material.

Dated this 16th day of August 2021


Vidya Bhaskar Singh Nandiyal
Patent Agent (IN/PA-2912)
Agent for applicant
, Description:FIELD OF INVENTION
[0001] Embodiments of the present invention relates to porous carbon material, more particularly it relates to a process for synthesizing a mesoporous carbon material using waste from a forging industry.

BACKGROUND
[0002] Porous carbon materials are ubiquitous and indispensable in many modern-day scientific applications. They are used extensively as electrode materials for batteries, fuel cells, and supercapacitors, as sorbents for separation processes and gas storage, and as supports for many important catalytic processes. Several types of porous carbon materials are divided into three categories based on their pore size distribution, microporous carbon material (pore size < 2 nm), mesoporous carbon material (pore size between 2-50 nm), macroporous carbon material (pore size >50 nm).

[0003] The mesoporous carbon material is a carbon material containing pores with diameters between 2 and 50 nm. Mesoporosity of the material increases a surface area of the material. Recently, there is a lot of interest in synthesis of the mesoporous carbon material with high surface area, where the high surface area is imperative for superior performance. The mesoporous carbon material is commonly synthesized using carbon precursors such as coal, polymers, carbides, metal ions as a raw material.

[0004] Every year a large amount of sludge or waste is generated from the industries such as forging, automotive, battery manufacturing, electric power plants, iron and steel industry, mines and quarries, nuclear industry, organic chemicals manufacturing, petroleum refining and petrochemicals etc. The generated sludge or waste is incinerated or applied to landfilling creating pollution. This sewage or waste is also used as fuel supports after treatment.

[0005] The industrial sludge or waste contains large number of organic compound, inorganic compound, heavy metals and pollutants. The industrial sludge or waste is used as a raw material in many industries such as cement industry, ceramic industry and construction industry etc.

[0006] However, there is a need for a process for synthesizing a mesoporous carbon material using an industrial waste as it contains large number of organic compounds, inorganic compounds, heavy metals and pollutants, thereby contributing to the pollution control.

SUMMARY
[0007] In accordance with an embodiment of the invention, a process for synthesizing a mesoporous carbon material using an industrial waste is provided. The process includes providing at least one of acid treatment, base treatment and effluent treatment to clean the industrial waste and to obtain dried powder. The process also includes removing iron from the dried powder to obtain a precursor composition. The process further includes carbonizing the precursor composition, in an inert atmosphere, to obtain the partial mesoporous carbon material. The carbonizing the precursor composition includes pyrolysing the precursor composition at a carbonizing temperature for a predefined duration for converting the precursor composition to the partial mesoporous carbon material. The process also includes processing the partial mesoporous carbon material to obtain the mesoporous carbon material. The process provides the mesoporous carbon material with high surface area and controlled size. The synthesized mesoporous carbon material exhibits good adsorption capacity and hydrogen storage capacity due to uniform pore size distribution.

[0008] To further clarify the advantages and features of the present disclosure, a more particular description of the disclosure will follow by reference to specific embodiments thereof, which are illustrated in the appended figures. It is to be appreciated that these figures depict only typical embodiments of the disclosure and are therefore not to be considered limiting in scope. The disclosure will be described and explained with additional specificity and detail with the appended figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The disclosure will be described and explained with additional specificity and detail with the accompanying figures in which:

[0010] FIG. 1 is a flow diagram representing the steps of a process for synthesizing a mesoporous carbon material using an industrial waste in accordance with an embodiment of the present disclosure; and

[0011] FIG. 2 is a flow diagram representing the steps of a process for removing the iron from the cleaned industrial waste in accordance with an embodiment of the present disclosure.

[0012] FIG. 3 is a graphical representation of Raman spectra of the synthesized mesoporous carbon material in accordance with an embodiment of the present disclosure.

[0013] Further, those skilled in the art will appreciate that elements in the figures are illustrated for simplicity and may not have necessarily been drawn to scale. Furthermore, in terms of the method steps, chemical compounds, and parameters used herein may have been represented in the figures by conventional symbols, and the figures may show only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the figures with details that will be readily apparent to those skilled in the art having the benefit of the description herein.
DETAILED DESCRIPTION
[0014] For the purpose of promoting an understanding of the principles of the disclosure, reference will now be made to the embodiment illustrated in the figures and specific language will be used to describe them. It will nevertheless be understood that no limitation of the scope of the disclosure is thereby intended. Such alterations and further modifications in the illustrated system, and such further applications of the principles of the disclosure as would normally occur to those skilled in the art are to be construed as being within the scope of the present disclosure.

[0015] The terms "comprises", "comprising", or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process or method that comprises a list of steps does not include only those steps but may include other steps not expressly listed or inherent to such a process or method. Similarly, one or more components, compounds, and ingredients preceded by "comprises... a" does not, without more constraints, preclude the existence of other components or compounds or ingredients or additional components. Appearances of the phrase "in an embodiment", "in another embodiment" and similar language throughout this specification may, but not necessarily do, all refer to the same embodiment.

[0016] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which this disclosure belongs. The system, methods, and examples provided herein are only illustrative and not intended to be limiting.

[0017] In the following specification and the claims, reference will be made to a number of terms, which shall be defined to have the following meanings. The singular forms “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise.

[0018] Embodiments of the present invention relates to a process for synthesizing a mesoporous carbon material using an industrial waste. The invention mainly focuses on the synthesizing of the mesoporous carbon material using waste from a forging industry. The invention provides cost effective and environmentally friendly process for synthesizing the mesoporous carbon material. The process provides the mesoporous carbon material with high surface area and controlled size. The synthesized mesoporous carbon material exhibits good adsorption capacity and hydrogen storage capacity due to uniform pore size distribution. The synthesized mesoporous carbon material can be used as a catalyst in different application. The synthesized mesoporous carbon material can be used as electrode material in fuel cells, battery and supercapacitor with higher deliverance rate. The synthesized mesoporous carbon material can be used in pharma industries for supporting the catalyst to enhancing reaction of the organic molecules.

[0019] FIG. 1 is a flow diagram (100) representing the steps of the process for synthesizing the mesoporous carbon material using the industrial waste in accordance with an embodiment of the present disclosure. The industrial waste includes the waste from the forging industry. In one embodiment, the industrial waste or sludge used here may include waste or sludge produced from automotive, battery manufacturing, iron and steel industry, electric power plants, mines and quarries, nuclear industry, organic chemicals manufacturing industry, petroleum refining and petrochemicals etc.

[0020] The process for synthesizing the mesoporous carbon material using the industrial waste begins with providing at least one of acid treatment, base treatment and effluent treatment to clean the industrial waste and to obtain dried powder at step 102. The acid treatment or base treatment is given to the industrial waste so that the industrial waste neither too acidic nor too alkaline for safe usage in further process.

[0021] In an embodiment, the process for synthesizing the mesoporous carbon material using the industrial waste includes removing iron from the dried powder to obtain a precursor composition at step 104. The precursor composition comprises a copolymer and one or more carbon materials. The copolymer comprises at least one of anionic copolymer, cationic copolymer and neutral copolymer, wherein the at least one of anionic copolymer, cationic copolymer and neutral copolymer being selected from a group comprising of Cetrimonium bromide (CTAB), Sodium Dodecyl Benzene Sulphonate (SDBS) and pluronic 123. The one or more carbon materials being selected from a group comprising of glucose, sucrose and fructose.

[0022] As used herein the term ‘precursor composition’ refers to a carbon precursor or any carbon-containing material such as a biomass, a biomass waste, an industrial waste, and products derived from the above materials.

[0023] The process for removing the iron from the dried powder includes providing a magnetic field to the dried powder with a magnet capacity ranging from 700 to 1000 bars to obtain the precursor composition. The magnetic field is configured to remove the iron at a flow rate of 50 to 100 kg/hr. As used herein the term ‘magnetic field’ relates to a vector field that describes the magnetic influence of electric charges in relative motion and magnetized materials.

[0024] In an embodiment, the precursor composition being carbonized in an inert atmosphere, to obtain the partial mesoporous carbon material at step 106. A carbonization of the precursor composition is carried by pyrolysing the precursor composition at a carbonizing temperature for a predefined duration for converting the precursor composition to the partial mesoporous carbon material. The carbonizing temperature for precursor composition is between 700°C to 1450°C. The predefined duration for converting the precursor composition to the mesoporous carbon material being 4 hours. The carbonizing of the precursor composition is carried in at least one of basic hydroxides medium, acidic medium and neutral medium. The inert atmosphere comprises at least one of N2 atmosphere, He atmosphere, Ar atmosphere and combination thereof.

[0025] As used herein the term ‘carbonization’ refers to a process in which a fuel is heated without air to leave solid porous carbon. As used herein the term ‘inert atmosphere’ refers to a nonreactive gas environment in which reaction can take place without the risk of contamination from reactive gases that exist in the air, such as oxygen and carbon dioxide.

[0026] In an embodiment, the process for synthesizing the mesoporous carbon material using the industrial waste includes processing the partial mesoporous carbon material to obtain the mesoporous carbon material at step 108.

[0027] The processing the partial mesoporous carbon material as mentioned in step 108 being carried by steps depicted by a flow diagram (200) provided in FIG.2, according to an embodiment.

[0028] The processing of the partial mesoporous carbon material begins with providing acid treatment or/and base treatment to the partial mesoporous carbon material to maintain pH at step 202. The partial mesoporous carbon material, post the acid treatment or/and base treatment, being dried at 100°C. As used herein, the term “pH” refers to a figure expressing the acidity or alkalinity of a solution on a logarithmic scale on which 7 is neutral, lower values are more acid and higher values more alkaline.

[0029] The processing the partial mesoporous carbon material also includes treating a dried partial mesoporous carbon material, obtained from the previous step, with one or more phosphates and one or more aldehydes at step 204. The partial mesoporous material treated with the one or more phosphates and the one or more aldehydes being dried at temperature between 150?C to 250?C to obtain the mesoporous carbon material. The obtained mesoporous carbon material possesses high surface area.

EXAMPLES

[0030] The present invention is explained further in the following specific examples which are only by way of illustration and are not to be construed as limiting the scope of the invention.
Example 1
[0031] The waste obtained from forging industry was carbonized at 900°C under inert atmosphere for a duration of 2 to 5 hours. The carbonized waste was further treated with alkali or acid at 90°C to 120°C for a duration of 10 to 12 hours. The mass was cooled and added distilled water with base till the pH become neutral. The solution was filtered and dried overnight at 100°C and observed for the product formation. The mesoporous carbon material (black colored powder) was obtained with the yield of 25 to 30%.

[0032] FIG. 3 is a graphical representation of Raman spectra of the synthesized mesoporous carbon material in accordance with an embodiment of the present disclosure. The graph confirms the predominant presence of highly porous carbon material at Raman shifts 1579,1399,1369 and 2682 cm-1.

[0033] The present invention provides the process for synthesizing the mesoporous carbon material using an industrial waste. The invention provides cost effective and environmentally friendly process for synthesizing the mesoporous carbon material. The process provides the mesoporous carbon material with high surface area and controlled size. The synthesized mesoporous carbon material exhibits good adsorption capacity and hydrogen storage capacity due to uniform pore size distribution. The synthesized mesoporous carbon material can be used as a catalyst in different application. The synthesized mesoporous carbon material can be used as electrode material in fuel cells, battery and supercapacitor with higher deliverance rate. The synthesized mesoporous carbon material can also be used in pharma industries for enhancing pharma reaction.

[0034] While specific language has been used to describe the disclosure, any limitations arising on account of the same are not intended. As would be apparent to a person skilled in the art, various working modifications may be made to the method in order to implement the inventive concept as taught herein.

[0035] The figures and the foregoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment. Moreover, the actions of any flow diagram need not be implemented in the order shown; nor do all of the acts need to be necessarily performed. Also, those acts that are not dependant on other acts may be performed in parallel with the other acts. The scope of embodiments is by no means limited by these specific examples.