A Novel and Large-Scale Rapid Green Synthesis of Few-Layer and Multi-Layer Graphene

Abstract

Mono-layer graphene has shown path-breaking potential in almost all areas that are useful to humankind. However, research in the last decade indicated that few-layer graphene (FLG) (3-10 layers) and multi-layer graphene (MLG) (>10 layers) could also be utilized for a wide range of applications. The synthesis of mono-layer graphene at a large scale is quite complex. Producing FLG and MLG at a kilogram scale is equally challenging. A vast amount of literature on different routes to prepare FLG and MLG is available. However, most of the preparation routes involve the use of hazardous chemicals, copious amounts of water, and thermal treatments and are time taking. Also, these processes need bigger machinery to convert the lab-scale methods into continuous large-scale production. On the contrary, in this work we report a novel process of producing FLG and MLG along with trace quantities of graphene (< 3 layers) developed using a kitchen mixer and a modified mixing jar (3 litres). The highlights of this process include the use of no hazardous chemicals/solvents, no washing or thermal treatment needed, much less time (30 minutes), and large quantity (250-500 grams) per batch. Our study successfully converted natural graphite flakes (NGF) into FLG and MLG by carrying out rapid liquid phase shear mixing using a green solvent. The shear mixing and the green solvent convert the NGF into FLG and MLG. The quantity of FLG and MLG getting produced is time-dependent. It has been optimized by thoroughly characterizing FLG and MLG using techniques like particle size analyser, X-ray diffraction, Raman spectroscopy, and electron microscopy. The conversion of NGF to FLG and MLG is also affirmed by studying changes in properties using tools like thermogravimetry, BET, and UV-visible spectroscopy. The developed process is rapid, efficient, economical, scalable, continuous, and, most importantly, chemical free.The graphenaceous powder produced unlike graphite can be easily coated on different substrates using appropriate binders and thus makes it useable for energy storage applications. Also the fine particle size of graphite makes is an ideal material to be used as lubricant, both in solid and liquid mediums. The developed material can be explored for its applications in several other areas which require FLG/MLG.