Facile synthesis of hard carbon microspheres from polyphenols for sodium-ion batteries: insight into local structure and interfacial kinetics

Hard carbons are the most promising negative active materials for sodium ion storage. In this work, a simple synthesis approach is proposed to produce hard carbon microspheres (CMSs) (with a mean diameter of ∼1.3 μm) from resorcinol-formaldehyde precursors produced via acid-catalyzed polycondensation reaction. Samples prepared at 1200, 1400, and 1500 oC showed different electrochemical behavior in terms of reversible capacity, initial coulombic efficiency (iCE), and the mechanism of sodium ion storage. The specific capacity contributions from the flat voltage profile (<0.1 V) and the sloping voltage region (0.1–1 V) showed strong correlation to the local structure (and carbonization temperature) determined by the interlayer spacing (d002) and the Raman ID/IG ratio of the hard carbons (HCs) and the rate of cycling. Electrochemical tests indicated that the HC synthesized at 1500 oC performed best with an iCE of 85–89% and a reversible capacity of 300–340 mAh g−1 at 10 mA g−1, with the majority of charge stored below 0.1 V. The d002 and the ID/IG ratio for the sample were ∼3.7 Å and ∼1.27, respectively, parameters indicative of the ideal local structure in HCs required for optimum performance in sodium-ion cells. In addition, galvanostatic tests on three-electrode half-cells cells revealed that sodium metal plating occurred as cycling rates were increased beyond 80 mA g−1 leading to considerably high capacity and poor coulombic efficiency, a point that must be considered in full-cell batteries. Pairing the hard CMS electrodes with Prussian white positive electrode, a proof-of-concept cell could provide a specific capacity of almost 100 mAh g−1 maintained for more than 50 cycles with a nominal voltage of 3 V.