November 10, 2024
Flake Graphite

Flake Graphite: Versatile Industrial Mineral with Wide Range of Applications.

Flake Graphite particles have rough, irregularly-shaped edges and appear almost translucent when held up to the light. It forms during the metamorphism of sedimentary carbonaceous materials like coal at high temperatures and pressures, deep below the Earth’s surface. Major deposits are found in countries like China, Brazil, North Korea and Canada.


Uses

Some key applications of it include:

Lubricants and Brake Linings: Due to its lubricating properties, it is used as an additive in grease, lubricants and brake linings. It helps reduce friction and prevents overheating during operation of machinery. Many automotive and industrial greases contain 5-30% flake graphite by weight.

Refractories: Flake graphite  possesses high thermal conductivity as well as resistance to heat. Refractory bricks and shapes containing 20-40% are employed in ladles, tundishes and other refractory linings used in steelmaking and glass production. They offer improved slag resistance and extended service lifetimes.

Foundry Facings: Graphite’s lubricating nature makes it suitable for use in foundry facings applied on the interior surfaces of molds and cores. Facings containing 20-30% graphite help in easy detachment of cast parts and provide a smooth surface finish.

Pencils and Crayons: Finely-ground flake graphite forms the “lead” in pencils and crayons. Its soft texture marks surfaces without smudging and can easily be removed or altered. Pencils may contain up to 90% graphite.

Fuel Cells: It is a component of modern fuel cell technologies that power automobiles, homes and infrastructure with hydrogen as fuel. It acts as a catalyst support material and improves electrical conductivity in proton exchange membrane fuel cells.

Lithium-ion Batteries: Consisting of layered sheets of carbon atoms, it is well-suited for use as the anode material in lightweight and rechargeable lithium-ion batteries. It intercalates lithium ions rapidly during charging and discharging cycles. A typical lithium-ion battery uses around 15-35% by weight.

Purification and Processing

Raw flake from mines requires extensive processing to obtain high-purity, specialized grades needed in industrial applications. The key steps involve:

– Crushing and grinding: Larger lumps of raw graphite are crushed and ground to obtain a fine powder. This disaggregates any attached impurities.

– Floatation: The powder is mixed with collectors, frothers and modifiers in flotation cells. Hydrophobic graphite particles attach to bubbles and float to the surface while hydrophilic impurities remain in suspension.

– Acid leaching: Hydrofluoric acid dissolves silicates and metals in an agitated leaching tank. Sodium or ammonium bifluoride increases acid penetration into crystalline structures.

– Thermal purification: Residual impurities are removed by heating the cleaned graphite powder in rotary kilns at temperatures between 2500-3000°C under an inert gas atmosphere.

– Size classification: Final sizing is done by air classification or sieving into various particle size fractions suitable for end applications. Mesh sizes range from -100 to -400.

– Milling/intercalation: Additional milling and intercalation processes may be used to remove surface oxides and expand/exfoliate graphite into specialized grades.

Trends and Future Outlook

A node of rapid growth is expected through 2027 driven by expanding applications such as lithium-ion batteries and fuel cells. The proliferating use of renewable energy solutions and electric vehicles is positively impacting graphite demand worldwide. China, as the dominant graphite producing country, is anticipated to remain the key supplier while new exploration projects also being developed in other nations. With high-purity graphite becoming more critical, upgraded production facilities are increasingly sought by manufacturers. Continued advancements in graphene and other carbon nanotechnologies may lead to novel applications of flake graphite over the long term. Overall, the natural flake graphite industry is poised for steady growth underpinned by widespread adoption of clean technologies across industrial and transportation sectors globally.

 

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*Note:
1. Source: Coherent Market Insights, Public sources, Desk research
2. We have leveraged AI tools to mine information and compile it

About Author - Priya Pandey
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Priya Pandey is a dynamic and passionate editor with over three years of expertise in content editing and proofreading. Holding a bachelor's degree in biotechnology, Priya has a knack for making the content engaging. Her diverse portfolio includes editing documents across different industries, including food and beverages, information and technology, healthcare, chemical and materials, etc. Priya's meticulous attention to detail and commitment to excellence make her an invaluable asset in the world of content creation and refinement. LinkedIn Profile 

 

About Author - Priya Pandey

Priya Pandey is a dynamic and passionate editor with over three years of expertise in content editing and proofreading. Holding a bachelor's degree in biotechnology, Priya has a knack for making the content engaging. Her diverse portfolio includes editing documents across different industries, including food and beverages, information and technology, healthcare, chemical and materials, etc. Priya's meticulous attention to detail and commitment to excellence make her an invaluable asset in the world of content creation and refinement. LinkedIn Profile   

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