Sulfur‐tuned advanced carbons (STACs) with high mass loadings of sulfur are synthesized using an environmentally benign and scalable steam‐assisted sulfur insertion (SASI) method. While steam provides the pressure necessary to promote deep and rapid sulfur insertion into a carbon porous structure, a strong affinity between melted sulfur and carbon excludes water from pore penetration. The resulting STACs exhibit sulfur mass loadings up to 85% and the electrical conductivity of the carbon framework is largely preserved. The sulfur penetration can be tuned to fill specific pore sizes, enabling pore‐size‐dependent allocation of sulfur and controllable porosity, while sulfur lines the carbon pore surfaces. A significant amount of sulfur is in the monoclinic γ phase. To demonstrate their energy and environmental applications, the STACs are used as cathode materials in rechargeable aluminum‐sulfur batteries and as adsorption materials for spilled oil removal.
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Abstract Chloroaluminate ionic liquids are commonly used electrolytes in rechargeable aluminum batteries due to their ability to reversibly electrodeposit aluminum at room temperature. Progress in aluminum batteries is currently hindered by the limited electrochemical stability, corrosivity, and moisture sensitivity of these ionic liquids. Here, a solid polymer electrolyte based on 1‐ethyl‐3‐methylimidazolium chloride‐aluminum chloride, polyethylene oxide, and fumed silica is developed, exhibiting increased electrochemical stability over the ionic liquid while maintaining a high ionic conductivity of ≈13 mS cm−1. In aluminum–graphite cells, the solid polymer electrolytes enable charging to 2.8 V, achieving a maximum specific capacity of 194 mA h g−1at 66 mA g−1. Long‐term cycling at 2.7 V showed a reversible capacity of 123 mA h g−1at 360 mA g−1and 98.4% coulombic efficiency after 1000 cycles. Solid‐state nuclear magnetic resonance spectroscopy measurements reveal the formation of five‐coordinate aluminum species that crosslink the polymer network to enable a high ionic liquid loading in the solid electrolyte. This study provides new insights into the molecular‐level design and understanding of polymer electrolytes for high‐capacity aluminum batteries with extended potential limits.