en.Wedoany.com Reported - Researchers at the University of Pittsburgh's Swanson School of Engineering have developed a lower-temperature process that converts ethane into battery-grade graphite and hydrogen, potentially offering a more energy-efficient route for producing critical materials used in lithium-ion batteries and clean energy systems.

The research originated from efforts to improve ethylene production efficiency through molten metal catalysis. During experiments, the team discovered that carbon byproducts from ethane dehydrogenation formed high-quality graphite structures rather than unwanted deposits. The process operates below 1,000°C, significantly lower than the approximately 3,000°C required for conventional graphite manufacturing.

Led by Götz Veser, a professor in the Department of Chemical and Petroleum Engineering, the research team investigated molten metal catalysis as an alternative to traditional steam cracking processes, which are energy-intensive and require periodic shutdowns to remove carbon buildup on reactor surfaces. In the molten metal system, carbon naturally separates from the reaction zone and floats to the surface, reducing fouling issues.

Mohammad Masnadi, an assistant professor and team member, stated in a press release that molten metal offers a surprising advantage: due to the extremely high density of liquid metal, carbon floats out and remains on top.

The researchers then determined that the resulting carbon material is battery-grade graphite suitable for lithium-ion battery applications. The process also simultaneously produces hydrogen as a co-product, adding potential value for energy and industrial markets.

The researchers have founded a startup, Graphonos Materials, to commercialize the technology. The company is raising funds to develop a complete benchtop-scale system capable of achieving kilogram-level daily production. Veser stated that the next phase will provide the engineering data needed to design a pilot plant.

The team noted that the process could support domestic graphite production while opening a low-emission pathway for converting natural gas feedstocks into materials needed for electrification and energy storage markets.

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