Fast Joule Heating for the Scalable and Green Production of Graphene with a High Surface Area

The rapid development of electric vehicles, unmanned aerial vehicles, and wearable electronic devices has led to great interest in research related to the synthesis of graphene with a high specific surface area for energy applications. However, the problem of graphene synthesis scalability, as well as the lengthy duration and high energy intensity of the activation processes of carbon materials, are significant disadvantages. In this study, a novel reactor was developed for the green, simple, and scalable electrochemical synthesis of graphene oxide with a low oxygen content of 14.1%. The resulting material was activated using the fast joule heating method. The processing of mildly oxidized graphene with a high-energy short electrical pulse (32 ms) made it possible to obtain a graphene-based porous carbon material with a specific surface area of up to 1984.5 m²/g. The increase in the specific surface area was attributed to the rupture of the original graphene flakes into smaller particles due to the explosive release of gaseous products. In addition, joule heating was able to instantly reduce the oxidized graphene and decrease its electrical resistance from >10 MΩ/sq to 20 Ω/sq due to sp² carbon structure regeneration, as confirmed by Raman spectroscopy. The low energy intensity, simplicity, and use of environment-friendly chemicals rendered the proposed method scalable. The resulting graphene material with a high surface area and conductivity can be used in various energy applications, such as Li-ion batteries and supercapacitors.