Few-layer graphene production through graphite exfoliation in pressurized CO2 assisted by natural surfactant

[Display omitted] •Pressured CO2 cardanol-based liquid exfoliation for quality graphene.•Cardanol concentration and sonication time yield promising results.•Innovative technique balances quality and cost for industrial graphene production.•Greener graphene with myriad applications: From supercapacitors to advanced materials. Graphene research has captivated researchers worldwide, propelling innovation across diverse industries. Through the liquid-phase exfoliation methodology of graphite powder, we have demonstrated a rapid route for obtaining few-layer and multi-layer graphene using a natural surfactant, cardanol. Aqueous phase exfoliation of graphite in the presence of cardanol as a surfactant was conducted to obtain pre-exfoliated graphite suspensions. The influence of different ultrasonication times, 10, 20, and 30 min, and contact times with the surfactant, 1 and 60 min, on the stability and concentration of dispersed exfoliated graphite was evaluated. Results indicate that ultrasonication for 20 min resulted in improved stability and reduced graphene flake sizes, making it suitable for scalable graphene production. Subsequently, the most stable dispersions of exfoliated graphite were subjected to CO2-pressurized treatment. Promising results were obtained when employing cardanol at its critical micelle concentration. The graphene exhibited good structural quality, low defect density, and small stacking, with an average size of 15 nm, where 40 % of the stacked graphene was smaller than 5 nm. The findings provide valuable recommendations for the scalable production of graphene with multilayers and a few layers (FLG/MLG), using cardanol, a friendly surfactant, and a novel method of exfoliation utilizing supercritical CO2. This technology represents an innovative approach, with potential applications in supercapacitors, solar cells, biosensors, polymer composites, and advanced materials.