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Abstract Solution‐processed graphene is a promising material for numerous high‐volume applications including structural composites, batteries, sensors, and printed electronics. However, the polydisperse nature of graphene dispersions following liquid‐phase exfoliation poses major manufacturing challenges, as incompletely exfoliated graphite flakes must be removed to achieve optimal properties and downstream performance. Incumbent separation schemes rely on centrifugation, which is highly energy‐intensive and limits scalable manufacturing. Here, cross‐flow filtration (CFF) is introduced as a centrifuge‐free processing method that improves the throughput of graphene separation by two orders of magnitude. By tuning membrane pore sizes between microfiltration and ultrafiltration length scales, CFF can also be used for efficient recovery of solvents and stabilizing polymers. In this manner, life cycle assessment and techno‐economic analysis reveal that CFF reduces greenhouse gas emissions, fossil energy usage, water consumption, and specific production costs of graphene manufacturing by 57%, 56%, 63%, and 72%, respectively. To confirm that CFF produces electronic‐grade graphene, CFF‐processed graphene nanosheets are formulated into printable inks, leading to state‐of‐the‐art thin‐film conductivities exceeding 104S m−1. This CFF methodology can likely be generalized to other van der Waals layered solids, thus enabling sustainable manufacturing of the diverse set of applications currently being pursued for 2D materials.
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This content will become publicly available on August 1, 2025
Bayesian Optimization of Environmentally Sustainable Graphene Inks Produced by Wet Jet Milling
Abstract Liquid phase exfoliation (LPE) of graphene is a potentially scalable method to produce conductive graphene inks for printed electronic applications. Among LPE methods, wet jet milling (WJM) is an emerging approach that uses high‐speed, turbulent flow to exfoliate graphene nanoplatelets from graphite in a continuous flow manner. Unlike prior WJM work based on toxic, high‐boiling‐point solvents such as n‐methyl‐2‐pyrollidone (NMP), this study uses the environmentally friendly solvent ethanol and the polymer stabilizer ethyl cellulose (EC). Bayesian optimization and iterative batch sampling are employed to guide the exploration of the experimental phase space (namely, concentrations of graphite and EC in ethanol) in order to identify the Pareto frontier that simultaneously optimizes three performance criteria (graphene yield, conversion rate, and film conductivity). This data‐driven strategy identifies vastly different optimal WJM conditions compared to literature precedent, including an optimal loading of 15 wt% graphite in ethanol compared to 1 wt% graphite in NMP. These WJM conditions provide superlative graphene production rates of 3.2 g hr−1with the resulting graphene nanoplatelets being suitable for screen‐printed micro‐supercapacitors. Finally, life cycle assessment reveals that ethanol‐based WJM graphene exfoliation presents distinct environmental sustainability advantages for greenhouse gas emissions, fossil fuel consumption, and toxicity.
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- Award ID(s):
- 2037026
- PAR ID:
- 10560124
- Publisher / Repository:
- Wiley
- Date Published:
- Journal Name:
- Small
- Volume:
- 20
- Issue:
- 33
- ISSN:
- 1613-6810
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
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