Petroleum coke (PetCoke) is a byproduct of oil refining that is commonly used as a heating resource and contributing to carbon emissions. Additionally, the presence of heavy metals and sulfur in PetCoke has also raised significant environmental concerns. Moreover, traditional high-temperature PetCoke treatment methods exacerbate greenhouse gas emissions. This study introduces an energy-efficient approach for converting PetCoke into carbon anode materials for solid-state batteries. Utilizing a custom-built laser-based vapor deposition setup, comprising a tube furnace and a nanosecond-pulsed infrared laser (1064 nm), we explored the PetCoke transfer process. Subjecting PetCoke to high power density laser irradiation generates localized high temperatures (~3000°C), initiating sample evaporation. By modulating the local conditions within the tube furnace, e.g., temperature, pressure, and argon flow rate, we can precisely control the kinetic gradient between the PetCoke and the plating substrate. This control is crucial for transforming PetCoke into various carbon forms with tailored microstructure and morphology, while selectively removing sulfur and heavy metals due to their differing nucleation rates on copper foil.One outcome of this process is the production of high-purity carbon black (C65) with a specific surface area of 400 m2/g, as verified by Brunauer-Emmett-Teller (BET) analysis. The exceptional surface area of C65 facilitates its use in creating a mixed-ionic-electronic conductor (MIEC) layer within all-solid-state batteries, enhancing lithium plating and stripping efficiency during cycling. Our battery design, incorporating C65/Ag/Solid Electrolyte/NMC811 and electrolyte composite, leverages laser-induced evaporation for C65 deposition on copper foil and employs Li6PS5Cl as the solid electrolyte. The resulting solid-state cell exhibits remarkable electrochemical performance, maintaining operation at an impressive current density of 2.4 mA/cm2 and achieving an average coulombic efficiency of 99.5% over 200 cycles.
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