Catalytic Graphitization of Tire Carbon Black for Battery Anodes

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Solution Overview

Problem

Existing methods for producing battery-grade graphite are energy-intensive, environmentally harmful, and inefficient, and carbon black waste from tire recycling lacks sufficient technical quality for reuse, leading to environmental pollution and waste accumulation.

Innovation Solution

A process that transforms carbon black from tire recycling into high-value graphitic carbon through a low-temperature catalytic method involving cleaning, activation, hydrothermal impregnation of catalysts, and graphitization, resulting in nanometric, spherical, and highly crystalline carbon suitable for lithium-ion battery anodes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional high-temperature graphitization (3000°C) is used to produce battery-grade graphite, then the crystallinity and electrochemical performance are improved, but the energy consumption and production cost increase significantly

Engineering Contradiction:

Improveelectrochemical performanceVSAvoidenergy consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The invention changes the temperature parameter from conventional 3000°C to a lower range of 2000-2500°C, combined with extended treatment time (2-4 weeks), to achieve graphitization with reduced energy consumption while maintaining acceptable electrochemical performance

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention performs preliminary carbonization at 800-1000°C before the final graphitization step, which prepares the carbon structure in advance and reduces the complexity and energy requirement of the subsequent high-temperature graphitization process

Inventive Principle:

Principle #10Preliminary action

2Reliability

If natural graphite is extracted and purified through conventional methods, then the graphite quality is improved, but the environmental impact and material loss increase significantly

Engineering Contradiction:

Improvegraphite qualityVSAvoidenvironmental impact

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The invention converts waste biomass carbon (a harmful environmental factor when discarded) into valuable battery-grade graphite, transforming an environmental problem into a beneficial resource utilization solution

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The invention uses transition metal catalysts as intermediaries to facilitate the transformation of biomass carbon into graphitic structure, enabling the process to occur at lower temperatures and with reduced environmental impact compared to conventional methods

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If synthetic graphite is produced through conventional processes, then the electrochemical performance is improved, but the material loss and greenhouse gas emissions increase significantly

Engineering Contradiction:

Improveelectrochemical performanceVSAvoidmaterial loss

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The invention utilizes waste biomass carbon as a feedstock, converting what would be discarded material into high-value graphite product, thereby eliminating material loss associated with conventional synthetic graphite production

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The invention employs lower graphitization temperatures (2000-2500°C compared to 3000°C) and extended treatment times, which improves material utilization efficiency and reduces greenhouse gas emissions while maintaining acceptable electrochemical performance

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The process produces graphitic carbon with specific capacity close to theoretical values, high stability, and Coulombic efficiency over 95%, addressing the environmental and waste issues while providing a viable anode material for lithium-ion batteries.

Implementation Method 1

the catalytic route turns out to be quite interesting considering that the working temperatures are lower and the reuse of the catalyst in the process is like the one exposed in the present development

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 2

These metallic particles catalyze the conversion of amorphous carbon into graphitic carbon according to a dissolution-precipitation mechanism

Methodology Applied

Scientific EffectDissolution-precipitation mechanism: Precipitation

Implementation Method 3

a process and its corresponding product that allow transforming carbon black waste derived from the recycling of tires, as well as other hard carbon from the industry, into a useful product

Methodology Applied

Scientific EffectGraphitization: Crystallisation

Data Source

PatentUS20260015238A1Process to produce battery anode grade graphitic carbon from by-products generated from recycled tires; and graphitic carbon obtained from the process

Publication Date: 2026.01.15 SUSTREND LAB SPA

AI summary

Recovered carbon black from recycled tires may be processed through several stages of: cleaning of the recovered carbon black; activation of the recovered carbon black; hydrothermal impregnation of catalyst in activated carbon of the recovered carbon black; graphitization of activated carbon of the recovered carbon black impregnated with catalyst; and finally, cleaning of graphite and recovery of catalyst.