Synthesizing hard carbon anodes for potassium-ion batteries from black liquor and deinking sludge

Porous hard carbon anodes, with large interlayer space and high adsorption ability, can offer much better cycle stability and higher discharge capacity for potassium-ion batteries compared to commercial graphite anodes. However, most commercial hard carbons are synthesized from relatively expensive high-molecular polymers. In this study, pulping and papermaking wastes were utilized as precursors for producing hard carbons and pore-enlarging agent, respectively. Specifically, after thorough mixing through ball milling, black liquor solids and deinking sludge were utilized to produce porous hard carbon anodes via co-pyrolysis. The results show that direct pyrolysis of black liquor can produce hard carbons efficiently, eliminating the need to extract lignin from black liquor. Moreover, it is shown that the pore-enlarging agent derived from deinking sludge can enlarge much portion of pores on hard carbons, resulting in abundant mesopores. Electrochemical tests demonstrate that the synthesized porous hard carbon anodes can achieve highest specific capacity of 303.5 mAh g⁻¹ at 100 mA g⁻¹ using a 1.0 M potassium hexafluorophosphate electrolyte in a mixture of diethyl carbonate and ethylene carbonate. Additionally, the synthesized porous hard carbon anodes exhibit low average capacity decay per cycle of 0.06 % at 100 mA g⁻¹ when tested with a 1.0 M potassium bis(fluorosulfonyl)imide electrolyte in the same solvent mixture after 500 cycles. Therefore, recycling black liquor and deinking sludge to produce porous hard carbon anodes for potassium-ion batteries is a promising approach for environmental and energy sustainability.