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Bulk synthesis of graphene nanosheets from plastic waste: An invincible


method of solid waste management for better tomorrow

Article  in  Waste Management · March 2019


DOI: 10.1016/j.wasman.2019.03.023

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Waste Management 88 (2019) 48–55

Contents lists available at ScienceDirect

Waste Management
journal homepage: www.elsevier.com/locate/wasman

Bulk synthesis of graphene nanosheets from plastic waste: An invincible


method of solid waste management for better tomorrow
Sandeep Pandey a,1, Manoj Karakoti a,1, Sunil Dhali a, Neha Karki a, Boddepalli SanthiBhushan b,
Chetna Tewari a, Sravendra Rana c, Anurag Srivastava b, Anand B. Melkani a, Nanda Gopal Sahoo a,⇑
a
Nanoscience and Nanotechnology Centre, Department of Chemistry, D.S.B. Campus, Kumaun University, Nainital 263001, Uttarakhand, India
b
Atal Bihari Vajpayee Indian Institute of Information Technology and Management, Gwalior 474015, Madhya Pradesh, India
c
Department of Chemistry, University of Petroleum & Energy Studies (UPES), Dehradun 248007, Uttarakhand, India

a r t i c l e i n f o a b s t r a c t

Article history: Waste plastic management and converting it into value added products is one of the greatest challenges
Received 28 November 2018 before the scientific community. The present work reports a cost effective, environment friendly and
Revised 7 March 2019 mass production capable method for upcycling of solid plastic waste into value added product (gra-
Accepted 13 March 2019
phene). A two step pyrolysis processes i.e. firstly at 400 °C in presence of nanoclay followed by at
750 °C under nitrogen atmosphere was performed to obtain a black charged residue. Raman spectroscopy
was performed on the obtained residue, where the observed D and G bands at 1342 cm1 and 1594 cm1,
Keywords:
respectively, confirm the synthesis of graphene nano sheets. In addition, a broad 2D band at 2790 cm1
DFT
Graphene
confirm the presence of few layer graphene nano sheets. The obtained graphene nanosheets were also
Plastic waste confirmed through the computational data by Gaussian09, where the peaks at 1379 cm1 and
Nanoclay 1596 cm1 for D and G band, respectively, make a good agreement with experimental data. TEM, FT-IR
Raman spectroscopy and EDX spectroscopy were also performed to confirm the synthesis of graphene nanosheets including
the functional group identification and quantitative analysis for elements, respectively.
Ó 2019 Elsevier Ltd. All rights reserved.

1. Introduction having enormous branches of application in every field of science


and technology including energy conversion and storage devices,
The extensive production and utilization of plastic to improve fuel cells, biosensors, supercapacitor, drug delivery, polymer
the standards of human life is posing disturbing situations for nanocomposites, etc (Choi et al., 2012; Liu et al., 2013; Hu et al.,
the ecosystem due to its non-degradable nature. Waste plastic 2014; Punetha et al., 2017). Several methods such as mechanical
management and converting it into value added products is one exfoliation of graphite with a scotch tape, chemical vapor deposi-
of the greatest challenges before the scientific community. Thus, tion (CVD) on metal surfaces, epitaxial growth on single-crystal
requiring urgent strategies for plastic solid waste management SiC, chemical coupling reactions, or exfoliation of graphite powder
with the potential to convert the ‘‘Waste to Wealth”. The techno- via solution oxidation, sonication/intercalation, etc are currently in
logical retardation in the recycling technology seems to be impor- use (Novoselov, 2004; Allen et al., 2010), however, the bulk pro-
tant to overcome the problem of solid plastic waste, where the duction of graphene nanosheets still reman a challenge.
charismatic application of nanotechnology provides an advantage Solid plastic waste is one of the prominent wastes that can be
over other recycling processes. The rise of carbon nano materials used as the precursor for the synthesis of graphene nano sheets.
bolster the technology of solid waste management to get the fruit- Thus, the approach to get graphene from solid plastic waste not
ful value added upcycling process. Especially, the conversion of only provides a solution to clean up the environmental issues
selective hazardous solid waste into graphene nano sheets has dri- caused by the solid waste, but also gives an alternative route for
ven the key technology. the value added recovery of this plastic waste. Several studies
Graphene, a two dimensional sp2 hybridized single atomic reported synthesis of high quality carbon nano materials from
sheet of graphite has rapidly emerged as a promising candidate plastic waste, where polypropylene (PP), polyethylene (PE) and
polystyrene (PS) shown their prominent potential to act as precur-
⇑ Corresponding author. sors to synthesize various forms of CNMs, such as carbon nano
E-mail address: ngsahoo@yahoo.co.in (N.G. Sahoo). fibers (CNFs), carbon nano tubes (CNTs) and carbon spheres (CSs)
1
These authors contributed equally to this work.

https://doi.org/10.1016/j.wasman.2019.03.023
0956-053X/Ó 2019 Elsevier Ltd. All rights reserved.
S. Pandey et al. / Waste Management 88 (2019) 48–55 49

(Wu et al., 2012; Wu et al., 2014; Acomb et al., 2014; Zhuo et al., ation of graphene nanosheets with the separation of all the value
2010, Zhuo et al., 2012; Zhuo and Levendis, 2014). Recently, nan- added fuels, waxes and gases. This phase belongs to the slow pyrol-
oclays have been employed with some solid wastes to get the 2- ysis up to 400 °C with the heating rate of 5 °C/min, which is neces-
dimensional carbon nano materials (Jiang et al., 2007; Gong, sary to remove all the oil containing hydrocarbons from the
2013; Song et al., 2009). The incorporation of nanoclays in waste plastics. This process involves the slow rate of the pyrolysis to
plastic provides an alternative, sophisticated and low cost method ensure that all the oil containing hydrocarbons and the gases
for synthesis of high quality graphene. Recently, one group demon- ranges from C1-C4 have been removed from the sample mixture.
strated the effect of organically modified montmorillonite clay Further, as the process of the pyrrolysis also contains waxy sub-
with polypropylene to get high quality graphene nano flakes stances, the slow rate of the pyrrolysis also reduces the tendencies
(Gong et al., 2014). of making waxy substances within the sample mixture, therefore
Several attempts have been made for recycling of solid plastic enhances the percentage of the purity level of the graphene
waste, however, failed to achieve an environment friendly and cost nanosheets during the final step. Once the process of the slow
effective upcycling of the waste. Herein, we are reporting the pyrrolysis has been completed, a black colored amorphous carbon
robust remediation for the conversion of solid plastic waste into type charred residue was obtained. Further, a simple ignition test
graphene nano sheets in mass production via cost effective method was also conducted for a number of randomly collected samples
using nanoclay. We demonstrate the synthesis of graphene from the bundles of the black residue obtained after the slow
nanosheets from waste plastic, the first step in the process involves pyrrolysis to ensure that all the oily hydrocarbons and waxy sub-
chopping of waste plastic into tiny pieces followed by washing, stances have removed during the slow pyrrolysis. The slow pyrol-
drying and mixing with bentonite. Thereafter, the mixture of waste ysis in this temperature causes the nucleation of amorphous,
plastic and bentonite is pyrolysed and followed by heating at high porous and shinning black charred residue, which was collected
temperature under nitrogen atmosphere to obtain graphene nano after the cooling of pyrolysis unit at room temperature (Fig. 1a).
sheets. The amorphous black charred residue thus collected from the pri-
The process is environmental friendly and cost effective in mary step is placed in the ball mill unit to make the ultra fine pow-
terms of mass scalability, as the precursor of product found in bulk der before undergoing the secondary heating process in inert
within the surrounding and by the aid of local municipality. Sec- atmosphere, to increase the productivity of the graphene nano
ondly the nanoclay used in the process as a degradation and trans- sheets in the system. The ultra fine powder thus obtained from
forming agent found cheaply and has almost zero toxic effect to the milling of amorphous carbon residue then undergoes fast heat-
both ecology and economy. In addition to it, the reactor success- ing process in the secondary reactor (consists a vertical cylindrical
fully removes all the gaseous hydrocarbons by using an inbuilt out- feeder unit with the capacity of 0.06 m3) at 750 °C with the heating
let pipe within the reactor and finally converted into fuels as a rate of 10 °C/min in inert atmosphere of N2 (20 ml/min), where
byproduct. As the present study focused on the value added pro- black colored graphene nanosheets were obtained (Fig. 1b). The
duct like graphene nanosheets which have the maximum eco- removal of used nanoclays is necessary to maintain the purity of
nomic values, the process is too viable for keeping the view of the product, which was achieved by washing with distilled water
ecology and economy. Beside this, almost zero waste has remained and mild acidic treatment with 5% HCl. After several experiments,
during the whole process, which is another specialty of the process. we have optimized these two temperatures to synthesize the few
Therefore, the present study motivates towards the process of layers of graphene successfully.
‘‘Trash to Treasure” for the wider scope of waste management
technologies.
2.2. Characterizations

2. Experimental Various spectroscopic and advance imaging techniques were


performed to confirm the successful synthesis of graphene nano
2.1. Materials and method sheets. Raman spectroscopy (RIRM-LPI519, excitation beam length
532 nm) was used to demonstrate the vibrational property of gra-
The methodology of producing graphene nano sheets from phene nano sheets. Fourier transform infrared spectroscopy was
waste plastics incurs several steps as summarized in the following performed by using Perkin Elmer, spectrum-2 for the confirmation
flow chart diagram (Fig. 1). Further, the production of graphene of chemical functionality in the graphene nano sheets. X-ray
nano sheets was achieved by following the previously reported diffraction (XRD) was performed using a Rigaku Miniflex-II by
method by our group (Sahoo et al., 2016). Briefly, the synthesis using Cu-Ka radiation of wavelength k = 1.5418 Å. TEM studies
process of graphene nano sheets was started by collecting the were carried out for internal morphology and structure of gra-
waste plastics (about 35 kg; categorized PP, PE and PS) from flea phene sheets performed under JEOL, JEM 2100 microscope. Ther-
market and local municipality. The collected plastics were chopped mogravimetric analysis was performed with TGA 4000, Perkin
(11.21 mm length, and 5.75 mm width) finely in flake like shape Elmer for graphitic nature, purity and percentage of volatile group
with the help of shredder. The chopped plastics then washed in a present in graphene nano sheets. The Electron dispersive X-ray
washing unit with soap solution to remove the oily and greasy spectroscopy (EDX) performed under XMax model number 71299
impurities, followed by drying. After performing these elementary for the quantitative analysis of elements present in graphene nano
stages of cleaning and drying, the waste plastics and bentonite sheets.
nanoclay with disk like particle shape (mean particle diameter of Apart from the utilization of advanced characterization tools to
70 nm, heavy metal was found 0.005% with a pH range of 9.0– confirm the synthesized material, we have also performed compu-
10.5) were mixed thoroughly with the help of sample mixture unit tational analysis for better understanding and theoretical valida-
in a definite ratio. This mixing of substrate with degradation tion of experimental results. Density Functional Theory (DFT)
reagent i.e. bentonite needs to be mixed properly in mixer. calculations utilizing Gaussian09 and QuantumWise-Atomistix
The sample mixture thus prepared has undergone slow pyroly- Toolkit (ATK) packages have been performed for validation of
sis (horizontal hollow cylindrical feeder unit with the capacity of raman spectra, and understanding of thermodynamic stability,
0.41 m3 made up of stainless steel) process in inert atmosphere electronic nature and quantum capacitance of defected graphene
of N2 gas at 400 °C. This step generates the backbone for the nucle- sheets.
50 S. Pandey et al. / Waste Management 88 (2019) 48–55

Fig. 1. The methodology flow chart for the production of graphene nano sheets, (a) physical state of carbon residue obtained from slow pyrolysis, (b) Skeleton structure of
graphene nano sheets after fast heating.

3. Results and discussion scattering of charge carrier that gives the strong D-peak, however,
this effect is less common for the Zig-zag edges, yet the D-peak
In order to appraise the success of above experimental strategy, intensity can be witnessed for some samples owing to the non-
various advanced techniques are used to confirm the synthesis of uniformity and irregularities in edge structure (Cançado et al.,
graphene nanosheets. Raman spectroscopy has been performed 2004; You et al., 2008). Besides, a broad 2D band also appears at
to confirm the synthesis of graphene and to assess its quality. Var- 2790 cm1, confirming the presence of few layer graphene nano
ious active modes are observed in the synthesized sample corre- sheets (Johra et al., 2014; Tu et al., 2014; Antony et al., 2015; Lou
sponding to the in plane and out of plane CAC bonding (Khan et al., 2017) but this 2D band is absent in the raman spectra of
et al., 2017). Here, we have performed the Raman spectra for the black charred residue. This clearly indicates that the black charred
black charred residue and graphene nano sheet obtained after residue at high temperature converts to few layers graphene
the two stage pyrolysis process ate 400 °C and 750 °C respectively. nanosheets. Beside these, theoretical and experimental data sup-
The spectrum obtain from the graphene nano sheets which shows ports that the longitudinal optical phonons are active only near
two prominent bands, one is D-band at 1342 cm1 due to stretch- the armchair edges, whereas the transverse optical phonons are
ing of sp3 carbons, and the other is G band at 1594 cm -1 due to active near to the zigzag edges, so the intensity of G-peak increases
stretching of sp2 carbons (Fig. 2a) (Kotov et al., 1996; Thomsen when the polarization of the excitation laser is analogous to arm-
and Reich, 2000). On the hand, these two peaks are also observed chair and vertical to a zigzag edges (Sasaki et al., 2010; Cong
in the black charred residue at D-band and G band at 1343 cm1 et al., 2010). The confirmation of synthesized graphene nanosheets
and 1569 cm1, respectively. The D band shows partially disor- has also been done through computation of Raman data from Den-
dered structures of sp2 carbon atom related to the structural sity Functional Theory (DFT) as implemented in Gaussian09 pack-
defects, while the G band shows the degree of graphitization asso- age (Frisch et al., 2003). The Raman data of graphene nanosheet
ciated with the first order scattering of sp2 carbon’s E2g vibrational having diameter approximately 12 Å has been plotted in Fig. 2b,
mode (Chen and Chen, 2015). The low intensity ratio of G band to D where the two prominent peaks at 1379 cm1 and 1596 cm1 cor-
band (IG/ID = 0.90, graphene nano sheet) specify the existence of respond to characteristic D and G bands, respectively. These peaks
anarchic and arbitrarily positioned graphene nanosheets (Sheng are in good agreement with the experimental result.
et al., 2011). The D/G band ratio changes in the presence of oxy- To further evaluate the presence the percentage of other func-
genated groups at upper and lower surfaces as well as edges of tionalities mainly oxygen containing groups and graphitic nature
sheet (Choi et al., 2006). Hexagonal structure of graphene nano of synthesized graphene nanosheets, thermogravimetric analysis
sheets shows two main types of edges: Zig-zag and armchair (TGA) has been performed (Fig. 2d) in the ambient environment
(Fig. 2d), where only armchair edges are responsible for the elastic to confirm the proper skeleton of the graphene nanosheets as the
S. Pandey et al. / Waste Management 88 (2019) 48–55 51

Fig. 2. (a) Raman spectra of graphene nano sheets (experimental); (b) Raman spectra from computational modeling, (c) Raman spectra of black charred residue (d) TGA curve,
(e) hexagonal structure of graphene nano sheets showing two main types of edges, zig-zag and armchair.

FT-IR spectra reported the presence of several oxygen containing weight loss was 44% of graphene nanosheets took place in two
functional groups within the graphene nanosheets. Here, the total stages i.e. at around the 50 °C to 400 °C and 500 °C to 800 °C. The
52 S. Pandey et al. / Waste Management 88 (2019) 48–55

first stage weight loss around 50 °C to 400 °C was a result of some behaviour of graphene nano sheets due to the extended aromatic
moisture and the removal of chemisorbed water molecules in the system. UV–Vis spectrum exhibited a maximum peak at 265 nm
graphene nano sheets (Hu et al., 2011; Gong et al., 2014), whereas, indicating the presence of few layer graphene nanosheets
the second stage major weight loss found at range between 500 °C (Krishnamoorthy et al., 2012; Haghighi and Tabrizi, 2013), which
and 800 °C is due to the removal of oxygen associated functional is further confirmed by transmission electron microscopy (Fig. 3c).
groups in the graphene nano sheets (Li et al., 2010). Transmission electron microscopy (TEM) has been performed to
The XRD spectrum shows three prominent peaks at 2h = 7°, 27° evaluate the growth and morphology of graphene nanosheets
and 50°, where the broad peak at 7° shows the functionalization of (Fig. 3d). From TEM images, it has been found that the obtained
graphene nanosheets, while the sharp peak at 27° and 50° are the graphene nanosheets show wrinkled morphology with arched
characteristic peaks of graphene nanosheets (Fig. 3a) (Wang et al., boundaries arised from the chemical bonding between carbon lay-
2008; Akbar et al., 2015; Das et al., 2018). Fourier transformation ers, however, at several places the morphology of graphene shows
infrared spectroscopy (FT-IR) was performed to identify the pres- an arranged array of regular sheets. The results also indicate that
ence of functional groups on graphene nanosheets (Fig. 3b). FT-IR the nucleation density must be controlled to achieve high quality
Spectra showed peaks at 1020 cm1, 1113 cm1, 1295 cm1, of graphene nano sheets, which can be obtained via controlled
1287 cm1, 1317 cm1, 1425 cm1, 1510 cm1, 1575 cm1, and pyrolysis temperature rate. Studies shown that slow increment of
1689 cm1 corresponding to carbon-oxygen, carbon-oxygen- temperature up to 400 °C provide low injection rate of carbon rad-
carbon in epoxy ring, strong OAH deformation & CAO stretching icals to achieve a low nucleation density, whereas, after 400 °C, the
vibronic interaction, aromatic double bond CAH in plane deforma- slow rate of temperature up to 750 °C causes merging of graphene
tion vibrations, combination of OAH deformation & CAO stretching nano sheets to form larger cluster type structures.
vibration, aromatic carbon- carbon double bond, and strong car- Further, EDX analysis was performed to recognize the chemical
bonyl stretching, respectively (Majidi and Ghaderi, 2018). The characterization and quantitative analysis for the occurrence of
presence of carbon-oxygen linkage shows a partial oxidation of oxygen containing groups on the surface as well as the edges of
the graphene nanosheets during the purification process. The peak graphene sheets (Fig. S1, Supporting Information). The obtained
at 1575 cm1 corresponding to carbon-carbon double bond for aro- data shows 76.99% and 21.1% of carbon and oxygen, respectively,
matic C@C bond supports the defined structure of graphene. UV– in the synthesized graphene nanosheets (Table S1, Supporting
Visible spectroscopy was carried out for analysing the absorbance Information), and a good distribution of carbon and oxygen within

Fig. 3. (a) XRD spectrum of graphene nano sheets, (b) FT-IR spectrum of graphene nano sheets, (c) UV–vis spectrum of graphene nano sheets, and (d) TEM images of graphene
nano sheets.
S. Pandey et al. / Waste Management 88 (2019) 48–55 53

the graphene nanosheets (Fig. S2, Supporting Information). Pres- the graphene sheets are simulated for their total energy and elec-
ence of oxygen in samples reveal the functionalization of graphene tronic structures on a HP proliant computing machine loaded with
nanosheets, supporting the results obtained via FT-IR and Raman ATK DFT code. The computations are performed by employing
spectroscopy. TEM images (Fig. 3d) also show some damages/ Perdew-Burke-Ernzerhof (PBE) functional within the Generalized
defects on graphene sheet due to the acid treatment during purifi- Gradient Approximation (GGA) as exchange-correlation functional.
cation process. The wave functions are expanded through Double-Zeta-Polarized
Interested in assessment of the defected graphene for energy (DZP) basis sets. The Brillouin zone has been sampled with a
storage applications, we performed the DFT calculations to evaluate 5 * 5 * 1 Monkhorst-Pack grid of k-points, and a high density mesh
the thermodynamic stability, electronic nature and quantum capac- cutoff of 130 Hartree utilized for calculation accuracy.
itance of defected graphene using QuantumWise-Atomistix Toolkit To study the impact of structural vacancies on graphene, the
(ATK) package (http://quantumwise.com/., 2018). ATK is the succes- graphene nano sheet has been subjected to vacancy defects of var-
sor of TranSIESTA-C code that is based on models, technology and ious concentrations viz. 1.38%, 4.16%, 6.94% and 9.72% (Fig. 4). All
algorithms as implemented in TranSIESTA (Brandbyge et al., 2002) the defects are realized on a 6 * 6 periodic hexagonal cell of gra-
and McDCal (Taylor et al., 2001) codes, employing localized basis phene, as depicted in Fig. 4a. The thermodynamic stability of gra-
sets as developed in SIESTA (Soler et al., 2002). The pristine as well phene with these structural imperfections has been assessed
as defected graphene sheets have been modelled using ‘Virtual with the help of formation energies (ELF) calculated per unit length
Nanolab‘, a powerful inbuilt graphical interface of ATK. Thereafter, of sheet, using Eq. (1) below,

Fig. 4. (a) 6 * 6 periodic hexagonal cell of defected graphene nano sheet, (b) quantum capacitance (CQ) of graphene with structural imperfections (defects) extracted from
their respective electronic density of states (DOS) profiles, (c) The pristine graphene shows perfect zero band gap at the C-point of brillouin zone, and (d-g) all the defect cases
[1.38%, 4.16%, 6.94%, and 9.72%] show metallic nature as observed through Fermi level crossing of energy bands.
54 S. Pandey et al. / Waste Management 88 (2019) 48–55

½Edefect  xEC  Raman, TEM, FT-IR and EDX spectroscopy were performed to con-
ELF ¼ ð1Þ
L firm the synthesis of graphene nanosheets including the functional
Here, Edefect and EC are the energies of defected graphene nano group identification and quantitative analysis for elements. This
sheet and Carbon atom, respectively; x is the number of carbon method is highly efficient and converted a 35 kg of solid plastic
atoms in the defected sheet and L is the length of the sheet waste into 5.25 kg of pure graphene nanosheets in a single batch.
(14.7 Å, in our case). The calculated formation energies are listed The synthesized graphene nanosheets have also been confirmed
in Table S2 (Supporting Information), where low formation energy by the raman spectra extracted from computational methods. Fur-
refers to high thermodynamic stability. It can be perceived from ther, the defected graphene has been analyzed by computational
Table S2 (Supporting Information) that, the formation energy study for thermodynamic stability, quantum capacitance and elec-
increases with the defect concentration implying reducing stabil- tronic properties and predicted its excellent suitability for energy
ity. Thus, it is evident that the thermodynamic stability decreases storage applications. Moreover, our synthesized graphene may be
with increasing defect concentration in the graphene nano sheets. used for various other applications such as solar cells, fuel cells,
All the formation energies listed in Table S2 are positive, indicating drug delivery, polymer nanocomposites, etc.
the endothermic nature of defect creation, where energy is
absorbed during the process. Though the defected graphenes offer Acknowledgements
relatively less stability in comparison to its pristine counterpart,
the defects are actually good for graphene when used for certain The work is supported by the National Mission of Himalayan
applications such as electrodes of energy storage supercapacitors Studies, Kosi Kataramal, Almora, India (Ref. No.: NMHS/MG-
and Li-ion batteries. Defects cause drastic enhancement in the 2016/002/8503-7) and Department of Science and Technology,
energy density of these devices due to enhanced electrolyte wetta- INSPIRE division (Ref No. IF150750), New Delhi, India.
bility, electronic nature and quantum capacitance, as illustrated
below. Appendix A. Supplementary material
The electronic nature of graphene with structural imperfections
(defects) is assessed through band structure calculations. As shown Supplementary data to this article can be found online at
in Fig. 4c, the pristine graphene shows perfect zero band gap at the https://doi.org/10.1016/j.wasman.2019.03.023.
C-point of Brillouin zone. The defects have transformed the elec-
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