Graphite Technology Collaboration and Commercialization Opportunity

Opportunity:

NETL is seeking collaboration to further develop and commercialize a low-temperature catalytic method for synthesizing highly crystalline, low ash content, graphite from coal, biomass, petroleum coke (PET coke), and/or plastics with recovery & reuse of catalyst & process acid.

Background:

Current methods for producing synthetic graphite involve the Acheson process which heats petroleum coke (PET coke) to extremely high temperatures (> 2800 C) for 3-5 days with material cooling occurring over a 2-3 weeks.  This method is extremely energy intensive, limited to a small set of expensive manufacturing feedstocks (e.g. premium PET coke), and lengthy to implement.  There is a need for methods that reduce energy consumption, reduce manufacturing time scales, and offer feedstock flexibility.  

Description:

NETL researchers developed a process for producing high quality synthetic graphite powders using an Fe-based catalyst.  The method reduces processing temperatures to <1500 C, reduces processing time to < 6 hrs, and is demonstrated to work with coal, biomass, plastics, petroleum coke (PET coke), coal mining waste, coal fines, and coal refuse.  The process includes a method for separating the catalyst from graphite product via acid leaching, recovery of both the catalyst and acid, and reuse of catalyst and acid in subsequent process runs without negatively impacting graphite quality.  The method can be practiced as a continuous process instead of the batch method used commercially for the Acheson process.  The NETL method successfully removes the Fe-catalyst residue and mineral matter residue left over in the graphite from both natural & waste-related feedstocks to parts per million levels, or better.  NETL’s unique approach offers opportunities to disrupt how synthetic graphite is manufactured by reducing energy consumption, reducing processing times, offering feedstock flexibility and producing highly crystalline, low-ash content, graphite.

Advantages/Benefits: 

• Reduced energy consumption
• Reduced processing times
• Reduced costs
• Feedstock flexibility; low cost feedstocks.

Potential Applications: 

• Lithium-ion battery (LIB) electrodes, Lithium iron phosphate (LFP) battery electrodes
• Moderator material for nuclear reactors
• Crucibles, electric arc furnace Electrodes (EAF), metallurgical electrodes, refractory materials
• DoD gunpowder, munitions
• Carbon-carbon composites, general graphite additive for composites

Development Status: 

Current stage of technology development: TRL ☐ 0-2     ☒ 3-5     ☐ 5-9

NETL has filed for patent protection on this invention.

NETL is seeking industry partners with ability to bring such inventions to the market. Moving critical technology beyond the Laboratory to the commercial world helps our partners gain a competitive edge in the marketplace through licensing and/or cooperative research and development collaborations. Interested parties can discuss this opportunity under non-disclosure agreements to protect company proprietary information. 

NOTE: THIS IS NOT A PROCUREMENT. Entities interested in developing technologies for manufacturing graphite should provide an electronic statement of interest, which includes the following:

1. Company Name and Address
2. The name, address and telephone number of a point of contact
3. A description of the relevant expertise and/or facilities

Please provide a complete statement to ensure consideration of your interest in this opportunity.

The subject heading in an email response should reference “NETL 25N-11” and be directed to Partnerships@NETL.doe.gov.