Mechanochemical process to produce exfoliated nanoparticles

Abstract

The invention relates to a mechanochemical process to produce exfoliated nanoparticles comprising the steps of providing a solid feedstock comprising a carbonaceous and/or mineral-based material; providing a flow of an oxidizing gas; introducing the solid feedstock and the flow of an oxidizing gas into a mechanical agitation unit, subjecting the material of the solid feedstock in the presence of the oxidizing gas to a mechanical agitation operation in the mechanical agitation unit at a pressure of at least 1 atm (15 psi). The invention further relates to nanoparticles obtainable by the mechanochemical process and to the use of such nanoparticles.

1 . A mechanochemical process to produce exfoliated nanoparticles, said method comprising the step of:
 subjecting the material of a solid feedstock in the presence of a gas comprising carbon dioxide to a mechanical agitation operation in a mechanical agitation unit at a pressure of at least 1 atm (15 psi), wherein the solid feedstock comprises a carbonaceous and/or mineral-based material.   
     
     
         2 . A mechanochemical process according to  claim 1 , wherein said carbonaceous material comprises at least one of the following materials: fly ash, bottom ash, incinerator ash, graphite, petroleum coke, anthracite coke, bituminous coal, activated charcoal and combinations thereof. 
     
     
         3 . A mechanochemical process according to  claim 1 , wherein said mineral-based material comprises at least one of the following materials: olivine, talc, yellowstone, serpentine, saw dust and combinations thereof. 
     
     
         4 . A mechanochemical process according to  claim 1 , wherein said oxidizing gas comprises a gas selected from the group consisting of oxygen, sulfur dioxide, nitrogen dioxide, and combinations thereof. 
     
     
         5 . A mechanochemical process according to  claim 1 , wherein said mechanochemical agitation operation comprises: mixing, stirring, shearing, shaking, blending or ultrasonication. 
     
     
         6 . A mechanochemical process according to  claim 1 , wherein said process further comprises the addition of a catalyst to said solid feedstock. 
     
     
         7 . A mechanochemical process according to  claim 6 , wherein said catalyst comprises a metal oxide selected from the group consisting of iron oxides, cobalt oxides, rhenium oxides, titanium oxides and combinations thereof. 
     
     
         8 . A mechanochemical process according to  claim 1 , wherein said process further comprises the step of introducing at least one intercalant agent. 
     
     
         9 . A mechanochemical process according to  claim 8 , wherein said intercalant agent comprises an acid selected from the group consisting of hydrochloric acid, sulfuric acid, nitric acid and combinations thereof. 
     
     
         10 . A mechanochemical process according to  claim 7 , wherein the catalyst is added through a lining on the inside wall of the mechanical agitation unit. 
     
     
         11 . A mechanochemical process according to  claim 1 , wherein said oxidizing gas comprises carbon dioxide gas emissions derived from industrial processes. 
     
     
         12 . A mechanochemical process according to  claim 1 , wherein said oxidizing gas comprises carbon dioxide at a level within the range of 70-95%.