Solar-thermal production of synthetic flake graphite from natural gas

This project aims to advance and commercially translate technology that uses concentrated solar radiation to convert natural gas directly into high-quality graphite and hydrogen. The solar-driven pyrolysis process involves no catalyst and releases zero CO2 as it captures carbon in the form of high-value graphite in a scalable, roll-to-roll (R2R) process. The pyrolysis process also produces a high-yield stream of hydrogen gas and minor hydrocarbons without releasing any atmospheric emissions. Our solar-driven co-production of graphitic carbon with hydrogen provides a means of supplying critical electrode materials for the rapidly growing Li-ion battery (LIB) market – driven by the exponential growth of electric-vehicle (EV), stationary-storage and defense applications – while also generating hydrogen for other uses. The primary objective is to demonstrate high-value graphitic carbon and hydrogen production from natural gas (NG) using a novel solar-driven thermal process with natural sunlight in the field, and then to assess the suitability of both solid and gas products for use in LIB anodes and fuels, respectively, including post-synthesis finishing processes. Phase I of this FastTrack proposal addresses implications of using commercial natural gas and continuous processing, while Phase II focuses on process efficiency and assessment of the products toward market needs. Current industrial processes that generate power, fuel, and various commodities are responsible for massive, ongoing greenhouse gas (GHG) emissions that adversely affect the stability of our climate—with potentially disastrous consequences. Moreover, these existing emission sources present a statutory challenge for the nation as it seeks to meet its carbon emissions reduction goals over the coming decades. Removing CO2 emissions from industrial processes and manufacturing is critical to sustainability. Today, no meaningful domestic supply of zero-emission synthetic graphite exists, and cost-effective production of clean hydrogen has proved elusive. SolGrapH’s financial projections indicate basic viability of the co-product business model. However, the projections require more detailed and comprehensive techno-economic analysis as they contain numerous coarse estimates ranging from technical assumptions, to market factors, to post-production finishing processes.