Researchers at the University of Kentucky are developing a process to convert coal into high-purity synthetic graphite for lithium-ion batteries, aiming to reduce reliance on imported materials and strengthen domestic supply chains.
The work is being led by Matthew Weisenberger at the university’s Center for Applied Energy Research, where coal is processed into battery-grade graphite suitable for use in applications ranging from consumer electronics to electric vehicles and stationary energy storage.
“People think lithium is the star of lithium-ion batteries,” said Weisenberger. “But there’s often 10 to 15 times more graphite than lithium. A single EV battery can require about 165 pounds of graphite.”
Graphite is a critical anode material in lithium-ion batteries, yet around 90% of global battery-grade supply is currently sourced from China. This concentration has raised concerns over supply security, particularly as demand grows across automotive and grid-scale storage markets.
Kentucky Team producing ultra-pure graphite
The Kentucky team is developing an alternative route using coal combined with refinery by-products to produce ultra-pure graphite. According to the researchers, the process avoids the more hazardous chemical treatments commonly associated with conventional synthetic graphite production.
The university said its facilities allow full vertical integration, from raw coal processing through to electrode fabrication and lithium-ion cell testing. Early results indicate a 39% increase in graphite yield compared with petroleum-based production methods, while maintaining comparable electrochemical performance.
In addition to graphite production, the process retains mineral by-products from coal that may contain rare earth elements. These materials could be used in other advanced technologies, including magnets and electronic components.
“This is about bridging Kentucky’s energy past with its advanced-materials future,” said Rodney Andrews, director of the Center for Applied Energy Research. “We’re turning a traditional resource into something essential for modern life.”
Photo: Matt Weisenberger and Aman Preet Kaur hold the progression of coal, from raw resource to finished battery. Photo by Jeremy Blackburn, University of Kentucky Research Communications.
