Mass production of graphene using high-power rapid joule heating method

Mass Production of Graphene Using the High-Power Rapid Joule Heating Method

Published in Chemical Engineering Journal (2025, Volume 505, DOI: 10.1016/j.cej.2025.159725)

This work introduces a scalable, low-cost approach for graphene synthesis via high-power rapid joule heating, enabling efficient production with exceptional material quality.

1. Scalable, Low-Cost Graphene Production

In our study published in Chemical Engineering Journal (2025, Volume 505, DOI: 10.1016/j.cej.2025.159725), we report a scalable approach for graphene synthesis using a high-power rapid joule heating method. 

This technique enables the production of 100 grams of graphene per batch within just 10 minutes, with a theoretical annual output of up to 5 tons under laboratory conditions. The energy consumption is approximately 5 kWh/kg, translating to a cost of roughly $0.50 per kilogram—significantly lower than that of conventional graphene production methods. 

The resulting graphene features a turbostratic structure with weak interlayer interactions, making it easy to disperse in various solvents. The process also allows for in-situ doping with heteroatoms such as boron and nitrogen, enabling precise tuning of electrical conductivity and surface polarity.

2. Preparation Process

In terms of the process, carbon-based precursors—including coal, petroleum coke, biochar, waste plastics, and rubber—are placed in a reaction vessel. A brief pulse discharge generates ultra-high temperatures within milliseconds, rapidly graphitizing the carbon source to form high-quality graphene. The process requires no catalyst, solvent, or inert gas atmosphere and produces no hazardous byproducts, making it inherently green and suitable for continuous production. For heteroatom doping, boron- or nitrogen-containing precursors can be introduced during the process, enabling the direct synthesis of functionalized graphene.

3. Product Features and Applications

Graphene products derived from this technology offer the combined advantages of high electrical conductivity, excellent dispersibility, and low cost. The turbostratic structure allows for uniform dispersion in water, organic solvents, and polymer matrices without the need for high-shear mixing. These materials are well-suited for a variety of applications, including composite additives, conductive coatings, energy storage electrodes, and rubber reinforcement. In-situ doping further imparts tailored properties such as hydrophobicity or catalytic activity, providing customized solutions for specific application needs.

4. Video and Access

The accompanying videos are supplementary materials from the paper, documenting the joule heating process in real time. These videos were produced by us and are fully owned by our company. For full access to the paper or further technical inquiries, please refer to the links below or feel free to reach out directly.