Porous carbon materials derived from discarded COVID-19 masks via microwave solvothermal method for lithium‑sulfur batteries

With the spread of COVID-19, disposable medical masks (DMMs) have become a significant source of new hazardous solid waste. Their proper disposal is not only beneficial to the safety of biological systems but also useful to achieve considerable economic value. The first step of this study was to investigate the chemical composition of DMMs. It is primarily composed of polypropylene, polyethylene terephthalate and iron, with fibrous polypropylene accounting for approximately 80% of the total weight. Then, DMMs were sulfonated and oxidised by the microwave-driven concentrated sulfuric acid within 8 min based on the fact that the concentrated sulfuric acid exhibits a good microwave absorption capacity. The co-doping of sulfur and oxygen was achieved while improving the thermal stability of DMMs. Subsequently, the self-activation pyrolysis of sulfonated and oxidised DMMs (P-SO@DMMs) was further realized in low-flow-rate argon. The specific surface area of P-SO@DMMs increased from 2.0 to 830.9 m2·g-1. P-SO@DMMs sulfur cathodes have promising electrochemical properties because of their porous structures and the synergistic effect of sulfur and oxygen co-doping. The capacity of the samples irradiated by microwave for 10 min at 0.1, 0.2, 0.5, 1, 2 and 5 C were 1313.6, 1010.9, 816.5, 634.4, 513.4 and 453.1 mAh·g-1, respectively, and after returning to 0.2 C and continuing the cycle for 50 revolutions, maintained 50.5% of the initial capacity. After 400 cycles, its capacity is 38.1% of the initial capacity at 0.5 C. It is slightly higher than the electrochemical performance of the sample treated by microwave for 8 min and significantly higher than the sample treated by 6 min. This work converts structurally complex, biohazardous DMMs into porous carbon with high specific surface area by clean and efficient microwave solvothermal and self-activating pyrolysis, which facilitates the development of carbon based materials at low cost and large scale.