High-yield and nitrogen self-doped hierarchical porous carbon from polyurethane foam for high-performance supercapacitors
Abstract
Confronted with the environmental pollution and energy crisis issues, upcycling of waste plastics for energy-storage applications has attracted broad interest. Polyurethane (PUR) is a potential candidate for the preparation of N-doped carbon materials. However, its low carbon yield limits the utilization of PUR waste. In this study, PUR foam was converted into N-doped hierarchical porous carbon (NHPC) through an autogenic atmosphere pyrolysis (AAP)-KOH activation approach. An ultra-high carbon yield of 55.0% was achieved through AAP, which is more than 17 times the carbon yield of conventional pyrolysis of PUR. AAP converted 83.2% of C and 61.0% of N in PUR into derived carbon material. The high conversion rate and self-doping effect can increase the environmental and economic benefits of this approach. KOH activation significantly increased the specific surface area of carbon materials to 2057 m 2 g-1 and incorporated hierarchical porous structure and O-containing functional groups to the carbon materials. The obtained NHPCs were applied to improve the performance of supercapacitors. The electrochemical measurement revealed that NHPCs exhibited a high specific capacitance of 342 F g-1 (133 F cm-3) at 0.5 A g-1, low resistance, and outstanding cycling stability. The energy density and power density of the supercapacitor were improved to 11.3 W h kg-1 and 250 W kg-1, respectively. This research developed a possible solution to plastic pollution and energy shortage.
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Zhou and colleagues converted polyurethane into highly nitrogen-doped hierarchical porous carbon (NHPC) using autogenous atmosphere pyrolysis combined with chemical activation, achieving an ultra-high carbon fixation rate of 55.0% (a 17-fold increase over conventional pyrolysis) and retaining 61.0% of the intrinsic nitrogen to form a self-doped structure.
“This process utilizes an in-situ controlled pyrolysis atmosphere to achieve an ultra-high carbon fixation rate of 55.0% (a 17-fold increase over conventional pyrolysis), simultaneously retaining 61.0% of the intrinsic nitrogen to form a self-doped structure.”
From Functional carbon materials from waste plastics: synthesis and applications (2025) · cites this paper as [129]
A supercapacitor assembled with NHPC achieved an energy/power density of 11.3 Wh/kg/250 W/kg.
“A supercapacitor assembled with this material achieved an energy/power density of 11.3 Wh/kg/250 W/kg.”
From Functional carbon materials from waste plastics: synthesis and applications (2025) · cites this paper as [129]
The polyurethane foam was pyrolyzed into N-doped porous carbon under in situ atmosphere, and the yield of hierarchical porous carbon obtained by KOH activation reached 55.0%.
“The polyurethane foam was pyrolyzed into N-doped porous carbon under in situ atmosphere, and the yield of hierarchical porous carbon obtained by KOH activation reached 55.0% (Fig. 4b) (Zhou et al. 2022).”
From Conversion of waste plastics into value-added carbon materials (2023) · cites this paper as Zhou et al. 2022
The polyurethane foam was successfully converted into N-doped porous carbon by in situ atmosphere carbonization and KOH activation, and the N-doped porous carbon as capacitor electrode had a high specific capacitance of 342 F/g at 0.5A/g, energy density of 11.3 W h/kg, and power density of 250 W/kg.
“The polyurethane foam was successfully converted into N-doped porous carbon by in situ atmosphere carbonization and KOH activation, and the N-doped porous carbon as capacitor electrode had a high specific capacitance of 342 F/g at 0.5A/g, energy density of 11.3 W h/kg, and power density of 250 W/kg (Zhou et al. 2022).”
From Conversion of waste plastics into value-added carbon materials (2023) · cites this paper as Zhou et al. 2022
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- Authors
- Zhou, X., Zhu, L., Yang, Y., Xu, L., Qian, X., Zhou, J., Dong, W., & Jiang, M.
- Affiliations
- Nanjing Tech University (CN)
- Corresponding author
- Dong, Weiliang
- Jiang, Min
- Venue
- Chemosphere
- Publisher
- Elsevier BV
- Published
- 2022-08
- Volume
- 300
- Pages
- 134552
- ISSN
- 0045-6535 (ISSN-L)
- OpenAlex
- W4223569047
- Cited by
- 49
- References
- 69
- Citations by year
- 2026: 7 · 2025: 12 · 2024: 8 · 2023: 13 · 2022: 9
- FWCI
- 2.42
- Type
- journal article
- Language
- en
- Open access
- closed
- Licence
- Locations
- Chemosphere (publishedVersion)
- PubMed (publishedVersion)
- Topics
- Physical Sciences › Materials Science › Electronic, Optical and Magnetic Materials › Supercapacitor Materials and Fabrication
- Physical Sciences › Energy › Renewable Energy, Sustainability and the Environment › Electrocatalysts for Energy Conversion
- Physical Sciences › Materials Science › Materials Chemistry › MXene and MAX Phase Materials
- Keywords
- polyurethane foam, nitrogen-doped carbon, hierarchical porous carbon, supercapacitors, KOH activation, plastic waste upcycling, carbon yield, specific capacitance, energy density, plastic pollution
- MeSH terms
- Carbon, Nitrogen, Plastics, Polyurethanes, Porosity
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