Natural GraphiteNatural Graphite,Characteristics, Markets &
21st Industrial MineralsCongress & Exhibition
Applications
Congress & ExhibitionBudapest
26 March 2012 – 29 March 2012
Presented byPresented byMathis Wissler &Andy Rill
Outline
Superior Graphite at a GlanceSuperior Graphite at a GlanceCharacterization of Carbon and Graphite
Classification of Carbon and GraphiteNatural Graphite Market
Production volume today dominance of ChinaProduction volume today, dominance of ChinaProcessing Characteristics and applications
Graphite Application Markets Traditional and EmergingMarket sizes and quality requirements
Graphite Market in 10 Years – Some Trends
Profile
• US Mid Sized Graphite and Carbon CompanyUS Mid Sized Graphite and Carbon Company• Family-Owned – 4th Generation• Since 1917— +95 years experience in graphite solutions
• Headquarters – Chicago, Illinois, U.S.A
• Employees – 320
• >150 million USD in sales – global and serving customers in>150 million USD in sales – global and serving customers in 50 countries
• Facilities 8 production sites; 4 R&D facilities• Facilities – 8 production sites; 4 R&D facilities
• ISO 9001:2008—certification
CapabilitiespAdvanced electro-thermal purification technology
Powder Processing (Milling, Blending, Screening)
Manufacture of engineered graphite electrodes
Manufacture of advanced ceramic shapes & powders
Manufacture of carbon coatings
MarketsAdvanced Ceramics Lead Acid BatteryAgricultureAlkaline Battery
yLi-Ion BatteryLubricantsy
AluminumArmor
Oil FieldPlasticsArmor
ElectronicsFriction Materials
PlasticsPolymersPowder MetalFriction Materials
Fuel CellsGraphite Foil
Powder MetalRefractoriesSteelGraphite Foil
IronSteelToner
LocationsEurope Headquarters, Sundsvall, SwedenPlants, Sundsvall, Sweden
World Headquarters, R&D, Chicago, IllinoisPlants, Bedford Park, Illinois
OfficesHöhr-Grenzhausen, Germany
PlantRussellville, Arkansas
OzarkGraphiteGraphiteSpecialties
PlantsHopkinsville, Kentucky
OfficeShanghai, China
Characterization of Carbon & Graphite Powders
Definition of Purity Definition of CrystallinityAsh ContentLoss of Ignition
Definition of PurityCrystallite Height LcCrystallite Width LaI t l Di t /2
e t o o C ysta ty
gMoistureImpurities Degree of Graphitization
Interlayer Distance c/2
Definition of TextureReal DensityB lk D it
Definition of Particle Size% passing mesh size
Bulk DensityTap Density
Surface Area Intergranular PorosityIntragranular Porosity
d100d90
d50Pore Size DistributionParticle Shape
g y d50d10
Classification of Carbon & Graphite Powders
Unstructured CarbonsCokeCoal
Petroleum CokeNeedleRegular
R l
Secondary Superior
Unstructured Carbons CoalPitch Coke
NeedleRegular
Anthracite
SyntheticPrimary
y SuperiorProcess
AchesonProcessGraphite
Micro-crystallineNatural Flake
Process
Macro-crystallineNatural FlakeVein
Nano Carbons
Nanotubes
FullerenesNano Carbons FullerenesGraphene
Diamond
Natural Flake Graphite
CharacteristicsLow to high purity • High crystallinity • Flake like particle shape
Purity AshMoisture
<0.1 – 20 %<0.1 – 2.0 %
Crystallinity GraphitizationLc
95-100 %100– 300 nm
Texture Real density 2 2 2 25 g/ccmTexture Real density 2.2- 2.25 g/ccm
Flake graphite occurs in three forms:• Fine flake graphite• Mid-sized flake graphite• Large-sized flake graphite (Madagascar)
Natural Flake Graphite
Steps of Purification
Excavation
Open pit
Mechanical Separation
Sorting
Flotation
Flotation
Purification
Chemicallyp pUnderground
gCrushingMillingScreening
Wet classificationy
Thermally
2 –20 % Carbon 50-90 % Carbon 95-98 % Carbon 99.5-99.99 % Carbon
Natural Flake Graphite Thermal PurificationSuperior Process Acheson Process
CharacteristicsHorizontal processHorizontal processModerately efficientHigh-purityEnvironmentally not unproblematic
Conductive Graphite Core
Coke GraphiteSiC + SiO2 + C SiC
SiO2 + C SiO2 + SiC + C
CharacteristicsVertical process
Removable Side WallHighly efficientHigh- purityEnvironmentally-friendly
Removable Side Wall
Natural Flake Graphite Main Markets
Carbon Brushes and PartsFrictionThermal InsulationLubricant AdditivesMetallurgyPackaging and Seals Worldwide 896’000
Chi 655’000*
Estimated world production (tpa)
Powder MetallurgyPrimary and Secondary Batteries
China 655’000*China Export 155’000
America’s 110’000Asia 60’000Af i 10’000Refractory Industry Africa 10’000Europe 21’000Others 40’000
* China Domestic Market 500’000 Source SG
Natural Flake Graphite Derivatives
Expanded graphite, a unique product
Sulfuric Acid
Expanded Natural Flake Graphite
CharacteristicsHigh purity High crystallinitySheet-like particle shapep p
Purity Ash <0.1 – 0.5 %
Estimated production Worldwide 30’000 tpa
Crystallinity GraphitizationLcLa
90 - 95 %30 nm85 nm
Source SG
Worldwide 30 000 tpaTexture Real density 2.2- 2.25 g/ccm
Main applicationsGraphite foils • Graphite seals • Thermal conductivity additiveElectrically conductive additive • Battery component
pp
Natural Flake Graphite Derivatives
Spherodized graphite, the anode for Li Ion batteries
Excavation Mechanical separation Flotation
Purification Spherodization Milling
2000 kg5%
198 kg50%
105 kg95%
Purification Spherodization Milling
70% loss
33 kg95%28.5 kg
99.95%
99 kg95%
S rface treatment
70% loss
Surface treatment30 kg
Coated GraphiteFor 1 EV Car
Natural Graphite Spherodized
CharacteristicsHigh purity High crystallinitySpherical particle shapeSpherical particle shape
Purity <0.1 %<0.1 %
Estimated production coated (tpa)Worldwide 19’000
Crystallinity GraphitizationLcLa
95 %80 nm100 nm
Japan 8’080*China 7’870Korea 1’800
Texture Real densityTap densityBET
2.2- 2.25 g/ccm>1.1 g/ccm<1.0 sm/g
Source SG
others 1’250*Precursor graphite from ChinaMain application – Li Ion batteries
g
Natural Vein Graphite
CharacteristicsVery high crystallinityLarge single crystalsPurity 95 98 % CPurity 95 – 98 % COccurs in large lumps Country of origin: Sri Lanka
Estimated productionW ld id 10 000 t
Source SG
Worldwide 10’000 tpa
Carbon brushes and parts • Lubricant additive • Coatings & dispersionsMain Applications
Conductive additives • Powder metallurgy
Micro-crystalline Graphite (amorphous)
CharacteristicsLow to moderate purityHigh degree of graphitizationLow crystallite sizeLow crystallite size
Purity Ash 50-90 %yMoisture 0.5 - 2 %
Crystallinity GraphitizationL
90 – 95 %20
Estimated production (tpa)Worldwide 180’000
Main Applications
Lc 20 nm China 110’000** North Korea 30’000Mexico 20’000Others 20’000Metallurgy • Lubricant additive • Friction
Refractory market • Paints • SealsSource SG
Others 20 000** Lutang Mines closed since 2010
Production capacity 700’000 tpa ?
Graphite, main application fields, traditionalGraphite, Main Application Fields, Traditional
Recarburizer (Metallurgy)
Market size >1,000,000 tpa
Specifications:pAlmost any carbon is used
Growth rate worldwide:
Quality Bench Mark Product
Growth rate worldwide:1-3 % pa
Quality Bench Mark ProductSuperior Graphite’s
Graphite, main application fields, traditionalGraphite, Main Application Fields, Traditional
Refractory Industry
Market size >160,000 tpa
Typical specifications:(source IM)
Large flake graphite > 500 micronPurity > 85% C
M k l d
Growth rate worldwide:1-3 % pa
Market leaderChinese manufacturers
Graphite, Main Application Fields, TraditionalFriction Industry (Friction Parts, Clutch Facings)
Market size 66’000 tpaG hi ( h i h fl k ) 19’000Graphite (synthetic, amorphous, flake) 19’000 tpaCalcined petroleum coke 47’000 tpaTypical specificationsTypical specificationsSynthetic graphite Particle Size 150 – 800 micron
Purity >99% C (no SiC)Amorphous graphite Particle Size < 75 micron
Flake graphite Particle Size variousPurity >90 % C
Amorphous graphite Particle Size < 75 micronPurity >80 % C
High end resilient friction modifier
Purity >90 % C
Growth rate worldwide 2-4 % pa
High end resilient friction modifierSuperior Graphite’s
Graphite, Main Application Fields, TraditionalLubricating industry (Dry lubricants, oils, greases)Market size ?N t l hit ( h fl k ) 56’000 tNatural graphite (amorphous, flake) 56’000 tpaSynthetic graphite ? Growth rate 3%Increasingly important market due to energy savings
Market Size 41’000 tpa ?Carbon brushes, carbon parts
Increasingly important market due to energy savings
Market Size 41’000 tpa ?Natural graphite (vein, flake) 40’000 tpaPrimary high crystallinity synthetic graphite <1’000 tpaGrowth rate 1 2% paGrowth rate 1-2% pa
M k t i 30’000 tGraphite Foils and SealsMarket size 30’000 tpa Large flake natural graphite high purityGrowth rate >3% pa
Graphite – Emerging MarketsLi Ion Batteries 2011
Market volume 2011 (tpa) of graphite and Carbon( ) gNatural graphite spherodized 19’000Synthetic graphite 10’000MCMB type 2’700MCMB type 2 700Hard Carbons 600Total 32’300 Source: SGC
Geographical distribution by anode material producersJapan 62%China 31%Korea 6%others 1%Application distributionApplication distributionConsumers and stationary 95%Electrical vehicles 5%
Source SG
Graphite – Emerging MarketsLi Ion batteries estimated demand 2020 (tpa)o 2C, E-bikes, power tools, others (ann. growth 6%) 48,000o E cars
Market share (%)
Anode graphite(1000 kg)
Graphite 30% yield (1000 kg)
Graphite 70% yield (1000 kg)
o E-cars
share (%) (1000 kg) yield (1000 kg) yield (1000 kg)
2 12’000 40’000 17’0005 30’000 100’000 42’000
Source SG10 60’000 200’000 84’000
Assumptions:CAGR N f t bil 2010 2020 32%• CAGR: No of automobiles 2010 – 2020: 32%
• Number of cars produced in 2010 (development countries excluded): 61 Million• Weight of graphite / carbon per car: HEV 3 kg
EV 30 kgEV 30 kg• Ratio HEV/EV 3/1
Graphite – Emerging MarketsLi Ion Batteries in electric cars: Plus and minuses
Positive factors for market growthg• Reduction of gasoline consumption• Reduction of green house gas emissions• Noise reductionNoise reduction • Application of latest technology• Inventive car design
Negative factors for market growth• Investment costs by consumer
C ffi i ll i h i i d b i i• Cost efficient small cars with optimized combustion engines• Mild hybrid cars with Carbon lead acid batteries• Electricity and raw material availability• Safety
Graphite – Other Emerging Markets
Thermal insulation in polymer foams
Thermo sinks , heat dissipation
Other thermal conductivity applications
Self lubricating engineering polymersSelf lubricating engineering polymers
Lead acid batteries for mild HEV
PEM fuel cells
New battery systems
Graphite Market in 10 Years, some TrendsGeneral RemarksStrategic importance in many applications due to unique characteristicsTrend to higher purity and controlled crystallinity, higher consistencyTrend to higher purity and controlled crystallinity, higher consistency
Replacement of natural graphite with primary synthetic graphite in specific applications
Preferred product to use because of environmental friendliness
MarketsLi Ion Batteries will play a major role in the overall growth
applications
Future of the E-Car not predictable (1%, 5%, 10% ……. share)Rising importance in the energy savings measures (lubrication)Significant market growth in electrical, electronic and thermal markets
SourcesChina will remain dominant but will protect sources with trade barriers
g g ,
New mines will open primarily in America’s, overcapacities to be expectedChina will remain dominant but will protect sources with trade barriers
Mines in Africa and Asia (excl. China) will still remain under development
Thank You for Your Attention