Development of Waste-Derived Carbon Functional Fluids for thermal management and tribological performance in electrified mobility

The growing adoption of electrified mobility is increasing the demand for efficient battery thermal management systems (BTMS), since lithium-ion batteries are highly sensitive to temperature and require effective thermal regulation to ensure performance, durability and safety. Maintaining an optimal operating temperature is essential to avoid accelerated degradation and safety issues. Consequently, increasing attention is being devoted to the development of advanced multifunctional fluids that combine thermal-management and tribological functions, enabling improved heat dissipation, friction and wear mitigation. At the same time, circular economy strategies promote the valorization of biomass waste and municipal solid waste (MSW) as feedstocks for high-value materials [2-3]. Recent studies have also shown that the incorporation of nanomaterials into base oils is an effective approach to improve heat-transfer performance, reduce friction and wear, although achieving long-term stability remains a significant challenge.

SENCHAR project investigates the transformation of biomass waste and MSW into modified carbons through thermal and microwave-assisted pyrolysis, followed by activation and functionalization processes. The resulting carbons are incorporated into water-based (glycol/water mixtures) and oil-based (bio-based ester) functional fluids. The influence of carbon characteristics, including particle size, porosity and surface chemistry, is evaluated through their effect on key fluid properties, including thermal conductivity, viscosity, electrical conductivity, dispersion stability and tribological performance (wettability, friction and wear).

Preliminary results indicate that the effectiveness of carbon-enhanced fluids depends more on surface engineering than on carbon loading. Based on these observations, the project shows functionalization strategies that improve dispersion stability, thermal and tribological performance, highlighting the potential of carbons as multifunctional tribological additives.

In conclusion, SENCHAR demonstrates the conversion of biomass and MSW into high-value carbon materials for thermal and tribological applications. By linking waste valorization with the development of next-generation functional fluids, the project contributes to circular-economy strategies  and supports the demand for sustainable technologies in electrified mobility.