Synthetic Graphite

- Overview

Synthetic graphite is a man-made material that's produced by treating amorphous carbon materials at high temperatures. It's often used in: Metal fabrication, Batteries, Solar panels.

Synthetic graphite is made from: 

• Calcined petroleum coke
• Coal tar pitch
• Natural and synthetic organic materials
• Hydrocarbons at temperatures above 2500 K
• Thermally unstable carbides
• Metal melts supersaturated with carbon

Synthetic graphite can have a purity of over 99% carbon. It's known for its ability to withstand high temperatures and corrosion. 

Synthetic graphite is more expensive, uses more energy, and has a much higher carbon footprint than natural graphite. There are processing facilities that will accept used synthetic carbon and graphite products. 

- Manufacturing Process

The manufacturing process of synthetic graphite includes various mixing, shaping and baking operations, followed by heat treatment to temperatures between 2500°C and 3000°C. Ultra-high heat treatment temperatures are required to drive the phase transition from solid/solid, amorphous carbon to graphite. 

Most synthetic graphite varies in morphology, from flakes in fine powders to irregular particles and needles in coarser products.

Synthetic graphite is processed at ultra-high temperatures, and the concentration of impurities contained in the precursor carbon is significantly reduced during processing. This occurs due to the high-temperature vaporization of volatile impurities, which at the process temperatures used include most metal oxides, sulfur, nitrogen, hydrogen, and all organic components that were part of the original petroleum or coal tar pitch.

After this heat treatment, almost all artificial graphite products are of high purity. Synthetic graphite is available in particle sizes ranging from 2 micron powder to 2 centimeter fragments. Carbon purity is typically 99.9+%. 

- Applications

Synthetic graphite is used in many applications including, but not limited to, friction, casting, electric carbon, fuel cell bipolar plates, coatings, electrolysis processes, corrosion products, conductive fillers, rubber and plastic compounds, and drilling applications.

• Friction Materials
• Energy Materials
• Powder Metallurgy
• Electrical Components
• Carbon Brushes & Parts
• Thread Components
• Drilling Mud Additives
• Rubber & Polymer Composites
• Packings & Seals

[More to come ...]