From waste to resource: Transforming Kraft black liquor into sustainable porous carbon fillers for radome applications

Abstract

The study addresses environmental and commercial challenges posed by weak black liquor (WBL) generated through the Kraft process in the paper industry. WBL, a toxic waste, annually reaches a staggering 1.3 billion tonnes globally. Currently, it is either incinerated for energy production or subjected to costly and complex chemical treatments to extract valuable compounds. Despite efforts to develop a scalable value-added material, the existing methods are inefficient in fully reusing WBL. Here, we report a simple chemical synthesis process that reuses 100 % of WBL without generating any waste materials; even salts recovered during the process might be reintegrated into the industry as chemical byproducts. Furthermore, given the simplicity and efficiency of the proposed synthesis methodology to transform WBL into a novel and sustainable porous carbon material, the carbon Kraft (CK). The process can also be scaled by using the right synthesis proportions and within a circular economy. CK exhibited desirable characteristics with a renewable content of 65 wt%, including a turbostratic graphitic-like structure (48.8 % graphitized), carbon content of 85 wt%, large specific surface area of 234.0 m2∙g−1, nanoporosity of 0.13 cm3∙g−1, and density of 1.92 g∙(cm3)-1. Moreover, CK showed electrical and thermal insulating characteristics, essential for use as fillers for elastomeric composite in electromagnetic transparent radome structures used to protect antennas and radars of unmanned aerial vehicles (UAV) from harsh environmental effects. Radomes were designed through the electromagnetic impedance match theory of half-wavelength calculations over specific frequencies of 1.3, 10, 15, 20, and 30 GHz. Results showed excellent transmission loss between −0.41 and −1.48 dB, representing 90.8 % and 70.5 % of transmittance, respectively.