Trash to treasure: Sulfonation-assisted transformation of waste masks into high-performance carbon anode for sodium-ion batteries

The global pandemic of COVID-19 poses significant challenge to the recycling of disposable polypropylene (PP)-based waste masks. Herein, a simple but effective sulfonation route has been proposed to transform PP-based waste masks into value-added hard carbon (CM) anode materials for advanced sodium-ion batteries. The sulfonation treatment improves the thermal stability of the PP molecule, preventing their complete decomposition and the release of massive gas molecules during the carbonization process. Meanwhile, the oxygen functional groups introduced during sulfonation effectively facilitates the cross-linking between the PP chains, hindering the rearrangement of carbon microcrystalline structures and enhancing its structural disorder. As a result, the prepared hard carbon anode (CM-180) with a high disorder degree and minimal surface defects realizes a high sodium storage capacity of 327.4 mAh g−1 with excellent cycle and rate capability. In addition, when coupled with O3–NaNi1/3Fe1/3Mn1/3O2 cathode, the fabricated sodium-ion full cell delivers a high energy density of 238 Wh kg−1 and achieves an outstanding rate capability with a retained capacity of 75 mAh g−1 even at an ultrahigh current rate of 50 C. This work offers a novel insight into transforming the waste masks to value-added hard carbons with promising prospects for sodium-ion batteries.