Graphite: An Essential Material in the Battery Supply Chain

Dec 26, 2023

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The following content is sponsored by Northern Graphite

The demand for lithium-ion (Li-ion) batteries has skyrocketed in recent years due to the increasing popularity of electric vehicles (EVs) and renewable energy storage systems.

What many people don’t realize, however, is that the key component of these batteries is not just lithium, but also graphite.

Graphite represents almost 50% of the materials needed for batteries by weight, regardless of the chemistry. In Li-ion batteries specifically, graphite makes up the anode, which is the negative electrode responsible for storing and releasing electrons during the charging and discharging process.

To explore just how essential graphite is in the battery supply chain, this infographic sponsored by Northern Graphite dives into how the anode of a Li-ion battery is made.

Graphite is a naturally occurring form of carbon that is used in a wide range of industrial applications, including in synthetic diamonds, EV Li-ion batteries, pencils, lubricants, and semiconductor substrates.

It is stable, high-performing, and reusable. While it comes in many different grades and forms, battery-grade graphite falls into one of two classes: natural or synthetic.

Natural graphite is produced by mining naturally occurring mineral deposits. This method produces only one to two kilograms of CO2 emissions per kilogram of graphite.

Synthetic graphite, on the other hand, is produced by the treatment of petroleum coke and coal tar, producing nearly 5 kg of CO2 per kilogram of graphite along with other harmful emissions such as sulfur oxide and nitrogen oxide.

The battery anode production process is composed of four overarching steps. These are:

Each of these stages results in various forms of graphite with different end-uses.

For instance, the micronized graphite that results from the shaping process can be used in plastic additives. On the other hand, only coated spherical purified graphite that went through all four of the above stages can be used in EV Li-ion batteries.

Despite its growing use in the energy transition all around the world, around 70% of the world’s graphite currently comes from China.

With scarce alternatives to be used in batteries, however, achieving supply security in North America is crucial, and it is using more environmentally friendly approaches to graphite processing.

With a lower environmental footprint and lower production costs, natural graphite serves as the anode material for a greener future.

Click here to learn more about how Northern Graphite plans to build the largest Battery Anode Material (BAM) plant in North America.

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This graphic from Wood Mackenzie shows how nickel and lithium mining can significantly impact the environment, depending on the processes used.

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The production of lithium (Li) and nickel (Ni), two key raw materials for batteries, can produce vastly different emissions profiles.

This graphic from Wood Mackenzie shows how nickel and lithium mining can significantly impact the environment, depending on the processes used for extraction.

Nickel is a crucial metal in modern infrastructure and technology, with major uses in stainless steel and alloys. Nickel’s electrical conductivity also makes it ideal for facilitating current flow within battery cells.

Today, there are two major methods of nickel mining:

From laterite deposits, which are predominantly found in tropical regions. This involves open-pit mining, where large amounts of soil and overburden need to be removed to access the nickel-rich ore.

From sulphide ores, which involves underground or open-pit mining of ore deposits containing nickel sulphide minerals.

Although nickel laterites make up 70% of the world’s nickel reserves, magmatic sulphide deposits produced 60% of the world’s nickel over the last 60 years.

Compared to laterite extraction, sulphide mining typically emits fewer tonnes of CO2 per tonne of nickel equivalent as it involves less soil disturbance and has a smaller physical footprint:

Nickel extraction from laterites can impose significant environmental impacts, such as deforestation, habitat destruction, and soil erosion.

Additionally, laterite ores often contain high levels of moisture, requiring energy-intensive drying processes to prepare them for further extraction. After extraction, the smelting of laterites requires a significant amount of energy, which is largely sourced from fossil fuels.

Although sulphide mining is cleaner, it poses other environmental challenges. The extraction and processing of sulphide ores can release sulphur compounds and heavy metals into the environment, potentially leading to acid mine drainage and contamination of water sources if not managed properly.

In addition, nickel sulphides are typically more expensive to mine due to their hard rock nature.

Lithium is the major ingredient in rechargeable batteries found in phones, hybrid cars, electric bikes, and grid-scale storage systems.

Today, there are two major methods of lithium extraction:

From brine, pumping lithium-rich brine from underground aquifers into evaporation ponds, where solar energy evaporates the water and concentrates the lithium content. The concentrated brine is then further processed to extract lithium carbonate or hydroxide.

Hard rock mining, or extracting lithium from mineral ores (primarily spodumene) found in pegmatite deposits. Australia, the world’s leading producer of lithium (46.9%), extracts lithium directly from hard rock.

Brine extraction is typically employed in countries with salt flats, such as Chile, Argentina, and China. It is generally considered a lower-cost method, but it can have environmental impacts such as water usage, potential contamination of local water sources, and alteration of ecosystems.

The process, however, emits fewer tonnes of CO2 per tonne of lithium-carbonate-equivalent (LCE) than mining:

Mining involves drilling, blasting, and crushing the ore, followed by flotation to separate lithium-bearing minerals from other minerals. This type of extraction can have environmental impacts such as land disturbance, energy consumption, and the generation of waste rock and tailings.

Environmentally responsible practices in the extraction and processing of nickel and lithium are essential to ensure the sustainability of the battery supply chain.

This includes implementing stringent environmental regulations, promoting energy efficiency, reducing water consumption, and exploring cleaner technologies. Continued research and development efforts focused on improving extraction methods and minimizing environmental impacts are crucial.

Sign up to Wood Mackenzie’s Inside Track to learn more about the impact of an accelerated energy transition on mining and metals.

We look at carbon emissions of electric, hybrid, and combustion engine vehicles through an analysis of their life cycle emissions.

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According to the International Energy Agency, the transportation sector is more reliant on fossil fuels than any other sector in the economy. In 2021, it accounted for 37% of all CO2 emissions from end‐use sectors.

To gain insights into how different vehicle types contribute to these emissions, the above graphic visualizes the life cycle emissions of battery electric, hybrid, and internal combustion engine (ICE) vehicles using Polestar and Rivian’s Pathway Report.

Life cycle emissions are the total amount of greenhouse gases emitted throughout a product’s existence, including its production, use, and disposal.

To compare these emissions effectively, a standardized unit called metric tons of CO2 equivalent (tCO2e) is used, which accounts for different types of greenhouse gases and their global warming potential.

Here is an overview of the 2021 life cycle emissions of medium-sized electric, hybrid and ICE vehicles in each stage of their life cycles, using tCO2e. These numbers consider a use phase of 16 years and a distance of 240,000 km.

While it may not be surprising that battery electric vehicles (BEVs) have the lowest life cycle emissions of the three vehicle segments, we can also take some other insights from the data that may not be as obvious at first.

As we move toward a carbon-neutral economy, battery electric vehicles can play an important role in reducing global CO2 emissions.

Despite their lack of tailpipe emissions, however, it’s good to note that many stages of a BEV’s life cycle are still quite emission-intensive, specifically when it comes to manufacturing and electricity production.

Advancing the sustainability of battery production and fostering the adoption of clean energy sources can, therefore, aid in lowering the emissions of BEVs even further, leading to increased environmental stewardship in the transportation sector.

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