Hengyang Industry
Graphite
Tel:+8615617816797
Graphite Production, Process & Key Use
Mail: sell@[Link]
Add: 500 West, cross road of Rizhao and Industrial road, Zhengzhou city, China
Introduction
There are two forms of graphite used in the world today, synthetic and natural. Graphite (natural and synthetic) can be
processed: die-molded, extruded, isostatic pressed, expanded, reinforced and coated. It can be transformed into yarns, foils
and sheets, tapes, boards, rigid and soft felts, powders.
General Production Process
Natural Graphite is Mined from ore deposits. There are mainly three forms of ore:
1. Amorphous ( Low Quality )
2. Flake ( small, medium and large)
3. Vein ( high quality )
Natural Graphite Production Process :
Mining:
Graphite is extracted from natural deposits through surface or underground mining. The raw ore is typically mixed with
other materials, requiring further processing.
Flotation:
The mined graphite ore undergoes froth flotation, where water and chemicals separate the graphite from impurities. This
results in a concentrate containing higher graphite purity.
Chemical Purification:
The graphite concentrate is chemically treated (often with acids) to remove remaining impurities. This step increases purity
to 99.95% or higher, required for battery-grade graphite.
Micronization:
The purified graphite is ground into fine particles to meet the size specifications for battery applications. This improves the
material’s suitability for further processing.
Spheronization:
The graphite particles are shaped into spherical forms to increase packing density and improve conductivity in the battery
anode. Spheronization enhances the material’s electrochemical performance.
Coating:
The spherical graphite is coated with a carbon layer, which enhances its conductivity and stability during battery cycling.
This coating also protects the graphite from side reactions.
Thermal Purification:
In a high-temperature furnace, any remaining impurities are vaporized, achieving ultra-high purity (>99.99%). This step
ensures the graphite meets stringent quality requirements for battery applications.
Synthetic Graphite Production Process :
The Acheson process is used to produce synthetic graphite, typically by heating carbon-containing materials at high
temperatures.
Raw Material Preparation:
Petroleum coke or other carbon-rich materials are mixed with a binder like coal tar pitch. The mixture is shaped into desired
forms, such as blocks or rods.
Placement in Furnace:
The shaped carbon material is packed with a sand-like material (silicon carbide) in an electric furnace to help control the
temperature during heating.
Heating (Graphitization):
An electric current is passed through the furnace, heating the material to temperatures around 2500–3000°C. At these
temperatures, carbon atoms rearrange into graphite’s crystalline structure.
Cooling:
The material is slowly cooled down over a period to ensure proper crystallization. Rapid cooling can cause cracking or
defects in the graphite structure.
Graphite Extraction:
Once cooled, the synthetic graphite is removed from the furnace, with impurities being brushed or blasted off.
Final Processing:
The synthetic graphite may undergo further shaping, cutting, or purification, depending on its intended application, such as
electrodes or battery-grade graphite.
Synthetic Graphite Production is ecologically more damaging. The Energy intensive Acheson process produces notable
amount of NOx, SOx and particulate matter pollutants.
Graphite Features
Property Comment
Thinnest material It can be as thin as only one carbon atom in thickness i.e. only ~0.345 nm thick
It is one of the hardest materials in the world, being harder than diamonds and 200 times
stronger than steel (1,100TPa/125 GPa) of the same thickness, but it is very flexible and
Stronger than steel
will not break. As an example, a graphene sheet 1 m2 in size could support a 4 kg cat, but
that sheet would weigh only as much as the cat’s whiskers.
Optical properties One atom thick layer sheets absorb ~2.3% visible light, making it transparent.
It weighs only 0.77 milligrams per square meter, and is stretchable up to 20% of its initial
Light and stretchable
length. It has the largest surface area to volume ratio of any material.
Impermeable It is completely impermeable. Even helium atoms cannot pass through it.
It is a perfect thermal conductor (over 5,000 W/mK), giving it five times the conductivity
Thermal conductivity
of graphite. It conducts heat in all directions i.e. it is an isotropic conductor.
It has the highest electrical current density (one million times that of copper), and the
Electronic properties highest intrinsic mobility (100 times that of silicon). It has a lower resistivity than any
other known material at room temperature.
It is an inert material and does not readily react with other atoms. However, it can “absorb”
Chemical properties different atoms and molecules, leading to changes in its properties. It can be functionalized
by several different chemical groups, resulting in different materials such as graphene
oxide and fluorinated graphene.
It is self–repairing. Graphene can self-repair holes in its sheets when exposed to molecules
Other qualities
containing carbon.
Reactive It is the most reactive form of carbon.
Graphite Application
Lubrication
Graphite powder is widely used as a dry lubricant in various industrial settings. Its ability to reduce friction and wear in
machinery stems from the weak van der Waals forces between its layers, allowing them to slide over each other easily. This
makes graphite an excellent lubricant, particularly in environments where liquid lubricants are impractical or undesirable,
such as:
High-Temperature Applications: Graphite can withstand extreme temperatures, making it suitable for use in
high-temperature furnaces and engines.
Chemical Resistance: In settings where chemical reactivity must be avoided, graphite provides reliable lubrication without
reacting with other substances.
Machinery and Equipment: Graphite powder is used to lubricate gears, bearings, and other moving parts, enhancing the
longevity and performance of machinery.
Conductive Materials
Graphite powder’s high electrical conductivity makes it an essential component in the production of conductive materials,
including:
Conductive Pastes and Coatings: Used in electronic devices, these pastes and coatings improve electrical connectivity and
performance in components such as printed circuit boards (PCBs).
Battery Electrodes: Graphite powder is a key material in the anodes of lithium-ion batteries, contributing to their high
energy density and efficiency.
Electromagnetic Interference (EMI) Shielding: Conductive coatings containing graphite powder are used to shield
electronic devices from EMI, ensuring proper function and reducing interference.
Refractory Materials
Due to its thermal resistance, graphite powder is a critical component in refractory materials designed for high-temperature
environments. Applications include:
Furnace Linings: Graphite powder is used to create heat-resistant linings for industrial furnaces, enabling them to
withstand intense temperatures without degrading.
Crucibles: Graphite crucibles are used for melting and holding metals and other materials at high temperatures, ensuring
the purity and quality of the molten materials.
Refractory Bricks and Tiles: These are used in the construction of kilns, incinerators, and reactors where high thermal
stability is required.
Powder Metallurgy
Graphite powder plays a crucial role in the alloying and sintering processes in powder metallurgy. Its applications in this
field include:
Lubricant in Sintering: Graphite powder acts as a lubricant during the sintering process, facilitating the compaction and
bonding of metal powders.
Alloying Agent: It is used to introduce carbon into metal powders, enhancing the properties of the final alloy, such as
hardness and wear resistance.
Die and Mold Release Agent: Graphite powder is applied to dies and molds to prevent sticking during the forming process,
ensuring the smooth release of the finished parts.
Electroplating
Graphite powder is used to create conductive surfaces on non-conductive objects, facilitating the electroplating process.
Applications include:
Conductive Primers: Graphite-based primers are applied to non-conductive substrates, enabling them to receive a metallic
coating through electroplating.
Electroforming: In this process, graphite powder is used to create molds or patterns that are later coated with metal,
allowing for the production of complex shapes and fine details.
Printed Circuit Boards (PCBs): Graphite powder is used to establish conductive paths in PCBs, ensuring efficient
electrical connectivity.
Additional Applications
Pencils and Writing Instruments: Graphite powder, mixed with clay, is used to produce the core of pencils, providing a
smooth writing experience.
Composites: Graphite powder is incorporated into polymer composites to enhance their mechanical and thermal properties,
used in automotive, aerospace, and sports equipment.
Fuel Cells: Graphite powder is used in bipolar plates and electrodes for fuel cells, contributing to their efficiency and
durability.
Graphite powder’s unique combination of electrical conductivity, thermal resistance, lubrication properties, and chemical
stability makes it indispensable in a wide range of applications, driving innovation and efficiency in numerous industries.