Synthetic Graphite from Biomass as Anode Material for 6T Batteries

Farad Power Inc. presents an innovative approach in the ONR STTR Phase II proposal, focusing on the development and scaling up of a novel, eco-friendly technology for producing battery-grade synthetic graphite. This method utilizes biomass-derived precursors, specifically leveraging agricultural waste materials such as sugarcane bagasse and corn cob, to synthesize high-purity (>99.95%) synthetic graphite. Our project aims to develop a domestic supply chain for graphite, a critical material in lithium-ion batteries (LIBs), by offering a secure, cost-effective, and environmentally friendly alternative to traditional graphite production, which is largely dependent on non-renewable sources and associated with significant environmental detriments. During the Phase I effort, Farad Power Inc. successfully demonstrated the feasibility of using biomass-derived furan-based polymers and evaluated and optimized the process parameters for one of the key unit processes - namely graphitization.  For the Phase II project, we propose to optimize the other key unit process - namely the polymerization of the furan chemicals (furfuraldehyde and furfuryl alcohol). Our goal is to identify the optimum combination of precursors for this polymerization reaction, to minimize the waste/residue and maximize the degree of polymerization to allow further efficiencies in the overall process.  This will also lead to lower process costs and benefit the implementation of a domestic supply chain for LIB-grade graphite. Through a strategic collaboration with Columbia University (as our university partner on this STTR), the team is well-equipped to understand and characterize the critical chemical reactions involved in the transformation of the precursor biomass extracts into high quality LIB-grade graphite. We propose utilizing MAS-NMR spectroscopic techniques that will allow us to track the reactions as they occur over temperatures up to ~ 150oC. Furthermore, our partnership with CONSOL Energy - a leading manufacturer of carbon-based products - allows us to leverage the expertise and facilities available at CONSOL Energy, and to scale up our carbonization and graphitization processes that follow the initial polymerization of the furan chemicals. We have also partnered with Navitas Systems - an existing supplier of 6T Batteries to the DoD organizations.  Our goal is to scale up the manufacturing process, synthesize a 50 Kg batch and sample to Navitas System for assembly into 6T Battery cells.  Testing of these cells will be performed and reported on. The successful implementation of our biomass-derived LIB-graphite promises significant contributions to national security by reducing dependency on foreign graphite sources, enhancing the resilience of the supply chain.