Development of Graphite and Hard Carbon Anode Materials

Scale-up and Industrial Production of Hard Carbon and Synthetic Graphite

The synthesis of carbon-based materials such as hard carbon and synthetic graphite for use as anode materials plays a central role in energy storage, particularly in battery technology. The demand for high-performance materials for lithium-ion batteries and novel energy storage technologies has driven the development of advanced carbon-based anode materials. The focus here is on the pyrolysis of organic precursor compounds such as polymers and petroleum coke. They provide carbon-rich starting materials that can be converted into hard carbon or graphite through high-temperature processes. In this context, however, there are considerable challenges in optimizing the structure, morphology and properties of these materials. At the same time, innovative solutions offer potential for improving manufacturing processes. In order to exploit the full potential of these materials, customized solutions are required that are precisely tailored to your specific needs. We can develop these with you!

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Warum maßgeschneiderte Anodenmaterialien?

The limitation of natural graphite deposits and the development of new cathode materials is leading to an increasing global demand for novel synthetic anode materials. By developing new types of anode materials, you can ensure that your innovative energy storage systems achieve the best results.

Optimization of performance parameters
The use of novel cathodes, especially for lithium and sodium ion batteries, requires the use of anodes adapted to them. Through customized solutions, we can ensure that your anodes provide the desired capacities, charging and discharging properties and thermal stability in these systems.

Increasing cycle life
Materials such as synthetic graphite and hard carbon offer different advantages in terms of cycle life and degradation behavior of innovative battery systems. Tailor-made anode materials help you to maximize the service life of your batteries.

Cost efficiency
Through the targeted selection and adaptation of materials, production processes can be optimized and costs reduced without compromising on quality.

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Basics of Pyrolysis and Carbon Formation for Anode Materials

Pyrolysis is a thermochemical process in which organic compounds are heated under oxygen-free conditions. During this process, complex molecules are split into smaller fragments, while volatile components escape and the carbon content remains behind. Depending on the precursor and process conditions, different forms of carbon can be created, from amorphous structures to hard carbon and crystalline graphite.

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Hard Carbon as an Anode Material

Hard carbon is characterized by its amorphous structure, which consists of disordered carbon layers. These materials have porosity and high surface areas, which makes them attractive for anode materials in sodium-ion batteries.

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Synthetic Graphite as an Anode Material

Synthetic graphite, on the other hand, is characterized by high crystallinity and an ordered layer structure. This leads to excellent electrical conductivity and high reversibility during lithium-ion transfer, which makes it particularly suitable for anodes in lithium-ion batteries.

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Challenges in the Pyrolysis of Organic Precursors

The choice of organic precursors and the control of pyrolysis conditions are crucial for the production of specific carbon structures. Precursors such as polymers and petroleum coke are particularly interesting as they are abundantly available and offer a good carbon yield. Nevertheless, some challenges arise during synthesis.

Structural control and homogeneity
One of the biggest challenges in the production of hard carbon and synthetic graphite from organic precursors is the precise control over the microstructure of the resulting material. During pyrolysis, many organic precursors tend to degrade unevenly, resulting in inhomogeneous carbon structures. This inhomogeneity can affect the performance of the final material as it influences electrical conductivity and ionic diffusion.

When using polymers as precursors, monomeric structure and degree of polymerization are important. Uneven degradation during pyrolysis often leads to a mix of amorphous and graphitic regions, resulting in unpredictable material properties.

Temperature and Process Control
Pyrolysis requires high temperatures, often over 1,000 °C, to achieve a graphitic structure. It is difficult to maintain a precise temperature gradient, which can lead to uneven heat distribution and inconsistent material development. Especially when converting petroleum coke into synthetic graphite, precise control of the temperature and heating rate is crucial to avoid unwanted defects.

Environmental Impact and Energy Efficiency
Pyrolysis is an energy-intensive process that requires not only high temperatures but also long residence times. This leads to high energy consumption and CO₂ emissions, which is a challenge in terms of sustainability. In addition, the pyrolysis of petroleum coke and polymers produces potentially harmful by-products that must be safely disposed of or further processed.

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Our offer: Development of Anode Materials According to Your Specifications

We offer you a comprehensive solution for the development of anode materials tailored to your specific requirements. Our approach includes consulting, development and scaling to ensure you get the best material for your application.

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Consulting and Requirements Analysis

The first step in developing customized anode materials is a thorough analysis of your specific needs. Our team of experienced engineers and scientists will work closely with you to define all relevant parameters. Our many years of experience in processing high-carbon materials in our thermal systems is your advantage.

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Material Development in the Laboratory

Once the requirements have been clearly defined, the development process begins in our state-of-the-art laboratories. Here we use advanced methods and techniques to develop anode materials that are precisely tailored to your needs.

Synthetic graphite: This offers an excellent balance between capacity, cycle life and cost efficiency. We develop and optimize synthetic graphite to adapt it perfectly to your specific applications.

Hard carbon: This material is characterized by its high specific capacity and stability at low temperatures. It is particularly suitable for applications where high energy and performance requirements are paramount.

We synthesize and modify these materials to ensure optimal performance and conduct extensive testing to ensure that the materials developed meet your requirements.

Scaling your Anode Material in the Pilot Plant

Once the anode material has been successfully developed, the next step is to scale it up. Our pilot plant facilities are designed to produce and test the materials developed in the laboratory on a larger scale.

Process optimization: During pilot production, processes are fine-tuned to maximize the efficiency and quality of the materials.

Pilot production: We produce small batches of the customized anode material to validate the production process and ensure a smooth transfer from laboratory to industrial production.

Quality control: We carry out strict quality control to ensure that every anode material produced meets the highest standards.