Turning biomass into battery-grade graphite

March 27, 2026

On March 25, 2026, scientists from the National Laboratory of the Rockies (NLR) and North Carolina State University (NCSU) revealed a major innovation in sustainable graphite manufacturing. Their new process converts biomass waste—such as agricultural residues and forestry byproducts—into high-quality graphite, a critical material widely used in batteries, steelmaking, and advanced industrial applications.

This development has significant implications for reducing U.S. dependence on imported graphite, particularly from China, while strengthening domestic production capabilities.

Turning biomass waste into high-value graphite

Conventional graphite production typically relies on mining or petroleum-based methods that require extremely high temperatures and energy-intensive processes. In contrast, the newly developed approach transforms renewable biomass into “bio-graphite” using existing refinery infrastructure.

The result is a graphite product that closely matches the quality of imported materials, while also producing usable fuel as a secondary output—making the process both efficient and economically attractive.

According to NLR chemical engineer Carrie Farberow, the research introduces dual production pathways that simultaneously generate graphite and fuels, improving both sustainability and cost-effectiveness.

Leveraging existing refinery equipment for graphite production

One of the most promising aspects of this innovation is its compatibility with current petroleum refinery systems. Traditionally, refineries heat residual tar through a delayed coking process, followed by calcination and graphitization at extremely high temperatures.

The research team adapted this process for biomass conversion. By applying fast pyrolysis in an oxygen-free environment, organic materials are converted into bio-oil. This intermediate product can then be upgraded into fuels or processed further into graphite using standard refinery equipment.

Researcher Steven Rowland noted that existing refineries could be repurposed to process abundant domestic biomass into valuable carbon materials, including graphite, without requiring significant infrastructure changes.

This approach allows U.S. manufacturers to produce locally sourced graphite for batteries and industrial use while meeting rising demand.

Low-temperature graphite production reduces costs

The second breakthrough focuses on lowering the temperature required for graphite formation. Instead of heating materials to approximately 3,000°C, researchers introduced an iron-based catalyst that enables graphitization at significantly lower temperatures—between 1,000°C and 1,500°C.

This advancement dramatically reduces energy consumption, lowers production costs, and allows for the use of more affordable furnace materials. Although the catalyst must be removed after processing, the method produces higher graphite yields and has been validated as economically viable through detailed analysis published in Bioresource Technology.

NLR battery expert Bertrand Tremolet de Villers emphasized that the team successfully demonstrated the full cycle—from biomass conversion to functional lithium-ion battery production—confirming both performance and safety in laboratory testing.

Unlocking the potential of U.S. biomass resources

The United States has vast untapped biomass resources, including forestry waste, industrial byproducts, and municipal waste streams. These materials can now be converted into valuable graphite for use in energy storage and manufacturing.

Data from the U.S. Department of Energy suggests that over one billion tons of biomass could be produced annually, with the potential to generate up to 100 million tons of battery-grade graphite each year through this technology.

Scaling up for industrial production

To bring this innovation to market, NLR is developing a pilot-scale delayed coking facility capable of processing large volumes of bio-oil into graphite and jet fuel. The produced graphite will undergo testing in large-scale lithium-ion batteries designed for grid energy storage applications.

Farberow highlighted that with sufficient investment, this technology could scale rapidly, helping to secure domestic graphite supply and strengthen U.S. manufacturing.

Why this matters for the future

This breakthrough represents a major step toward:

• Reducing reliance on foreign graphite imports
• Supporting clean energy and battery production
• Creating value from waste materials
• Lowering manufacturing costs and emissions

By transforming biomass into a strategic industrial resource, this innovation could reshape the global graphite market and accelerate the transition to sustainable energy systems.