Provided are graphitic carbon materials and methods of making graphitic carbon materials. Also provided are compositions of the graphitic carbon materials with nanoparticles disposed thereon and methods of making the compositions. Also disclosed are devices utilizing the graphitic carbon materials and/or the compositions. The graphitic carbon materials are porous and have a desirable graphitic content. The graphitic materials may be nitrogen- and/or metal-doped. The nanoparticles may be platinum or platinum/transition metal nanoparticles. The compositions may be used in oxygen reduction reaction applications.

Provided are graphitic carbon materials and methods of making graphitic carbon materials. Also provided are compositions of the graphitic carbon materials with nanoparticles disposed thereon and methods of making the compositions. Also disclosed are devices utilizing the graphitic carbon materials and/or the compositions. The graphitic carbon materials are porous and have a desirable graphitic content. The graphitic materials may be nitrogen- and/or metal-doped. The nanoparticles may be platinum or platinum/transition metal nanoparticles. The compositions may be used in oxygen reduction reaction applications.

A method of producing graphite may include beneficiating an amount of coal to form a coal char, grinding the coal char to produce a crushed char and placing the crushed char in a porous container. Then, the method includes immersing the porous container in a molten salt bath. The molten salt bath includes a graphite anode. The method further includes applying an electrical potential across the porous container and the graphite anode such that a graphite deposit forms on the graphite anode. The graphite anode is removed from the molten salt bath and the graphite deposit is separated from the graphite anode to produce graphite fragments.

A method of producing graphite may include beneficiating an amount of coal to form a coal char, grinding the coal char to produce a crushed char and placing the crushed char in a porous container. Then, the method includes immersing the porous container in a molten salt bath. The molten salt bath includes a graphite anode. The method further includes applying an electrical potential across the porous container and the graphite anode such that a graphite deposit forms on the graphite anode. The graphite anode is removed from the molten salt bath and the graphite deposit is separated from the graphite anode to produce graphite fragments.

A two-stage method of producing purified graphite is described. The first stage of the method comprises the steps of subjecting graphite material to a caustic bake and releasing any remaining caustic using water. The graphite material is then subjected to a first acid wash. Neutralising and washing the acid washed graphite material is then performed to deliver an intermediate purified graphite product. In the second stage the intermediate purified graphite product is subjected to a low temperature caustic leach. Any remaining caustic in the intermediate purified graphite product is released using water, and the intermediate purified graphite product is subjected to a second acid wash. Finally, neutralising and washing the intermediate purified graphite product is performed to deliver a final purified graphite product with a purity of 99.95% C and above.

A two-stage method of producing purified graphite is described. The first stage of the method comprises the steps of subjecting graphite material to a caustic bake and releasing any remaining caustic using water. The graphite material is then subjected to a first acid wash. Neutralising and washing the acid washed graphite material is then performed to deliver an intermediate purified graphite product. In the second stage the intermediate purified graphite product is subjected to a low temperature caustic leach. Any remaining caustic in the intermediate purified graphite product is released using water, and the intermediate purified graphite product is subjected to a second acid wash. Finally, neutralising and washing the intermediate purified graphite product is performed to deliver a final purified graphite product with a purity of 99.95% C and above.

Methods for processing black mass material from lithium-ion battery recycling processes include fractionating the black mass into a lithium fraction, a graphite fraction, and a concentrated metal powder fraction. This is accomplished using a multiphase liquid blend of nonpolar hydrophobic solvent and water to dissolve the lithium and produce a multiphase admixture which, upon gravity separation, produces a graphite layer in the hydrophobic solvent and a mixed metal powder layer that sinks to the bottom of the aqueous layer.

Methods for processing black mass material from lithium-ion battery recycling processes include fractionating the black mass into a lithium fraction, a graphite fraction, and a concentrated metal powder fraction. This is accomplished using a multiphase liquid blend of nonpolar hydrophobic solvent and water to dissolve the lithium and produce a multiphase admixture which, upon gravity separation, produces a graphite layer in the hydrophobic solvent and a mixed metal powder layer that sinks to the bottom of the aqueous layer.

The present invention relates to a composition for the production of a graphite powder, suitable for making high performance lithium-ion battery anodes and other applications. The composition of matter comprises a biochar, a metal and graphite. The biochar is typically derived from the pyrolysis of woody biomass. The metal is typically a transition metal derived from the decomposition and reduction of an organic or inorganic metallic compound. The graphite is highly crystalline and has a wide range of morphologies or structures.

The present invention relates to a composition for the production of a graphite powder, suitable for making high performance lithium-ion battery anodes and other applications. The composition of matter comprises a biochar, a metal and graphite. The biochar is typically derived from the pyrolysis of woody biomass. The metal is typically a transition metal derived from the decomposition and reduction of an organic or inorganic metallic compound. The graphite is highly crystalline and has a wide range of morphologies or structures.