Facile large-scale synthesis of three-dimensional graphene-like ordered microporous carbon via ethylene carbonization in CaX zeolite template

Recently, our laboratory has developed a zeolite-templated synthesis route to microporous three-dimensional (3D) graphene-like carbons via lanthanum-catalyzed carbonization of ethylene. In the present work, we optimized the ethylene carbonization conditions for a zeolite X template, using an inexpensive Ca²⁺-ion catalyst instead of La³⁺-ion catalyst. This synthesis gave a high carbon yield based on the template pore volume, and exhibited no significant amount of carbon deposition on the external surfaces. Single crystal X-ray diffraction analysis indicated that the carbon had 3D graphene- or nanotube-like frameworks along the surface of the zeolite pore walls, similar to the case of La³⁺ catalyst. With a 70-g batch of carbon synthesis, we demonstrated the potential of this synthesis route for large-scale production that would bring about a wide range of practical applications.