Graphite

Natural Flake Graphite is an industrial mineral with unique properties primarily due to its structure

  • It is a pure form of carbon where flat hexagonal platelets are stacked on each other like a deck of cards, held together by relatively weak intermolecular forces.
  • It is a mineral with very anisotropic properties, that is, the partical’s electrical, thermal, physical and chemical properties are different in the plane axis along the layers of platelets than in the vertical axis going through the layers. Like a metal, it has high electrical and thermal conductivity along its planar axis, yet relatively poor going through the layers.
  • These weakly bonded layers give graphite its slipperiness or lubricity.
  • Paradoxically, graphite is one of the softest minerals, yet stronger per unit weight than steel.
  • It's strength increases as its temperature is increased.
  • Graphite absorbs energy regardless of the source making it ideal for sports equipment such as tennis racquets, fishing rods, golf clubs, etc.
  • It is inert to almost all substances including corrosive chemicals even at elevated temperatures making it ideal for gaskets, packing material, brake and clutch plates, etc.
  • Graphite is replacing asbestos in many areas because of the hazards associated with that mineral.
  • Graphite can withstand a wide range of temperature from very cold levels to >3000°C in inert and reducing atmospheres and vacuum making it invaluable in many applications ranging from cryogenic to nuclear reactor temperature levels.
  • Graphite acts as a neutron moderator, a requirement for thermal nuclear reactors.
  • Graphite flake can be exfoliated into thinner and thinner sheets much like expanded vermiculite or popcorn when heated under controlled conditions.
  • If exfoliation is taken to the extreme, individual sheets of "graphene" can be formed. These are one-atom thick layers of carbon with properties that rival steel in strength, silicon in quality for integrated circuitry, and copper in electrical conductivity.
Combinations of these properties makes graphite truly unique and ideal for existing applications with many more uses on the horizon.

Uses of natural graphite (http://en.wikipedia.org/wiki/Graphite)

Natural graphite is mostly consumed for refractories, steelmaking, expanded graphite, brake linings, foundry facings and lubricants. Graphene, which occurs naturally in graphite, has unique physical properties and might be one of the strongest substances known; however, the process of separating it from graphite will require some technological development before it is economically feasible to use it in industrial processes.


Refractories
This end-use begins before 1900 with the graphite crucible used to hold molten metal; this is now a minor part of refractories. In the mid 1980s, the carbon-magnesite brick became important, and a bit later the alumina-graphite shape. Currently the order of importance is alumina-graphite shapes, carbon-magnesite brick, monolithics (gunning and ramming mixes), and then crucibles.

Crucibles began using very large flake graphite, and carbon-magnesite brick requiring not quite so large flake graphite; for these and others there is now much more flexibility in size of flake required, and amorphous graphite is no longer restricted to low-end refractories. Alumina-graphite shapes are used as continuous casting ware, such as nozzles and troughs, to convey the molten steel from ladle to mold, and carbon magnesite bricks line steel converters and electric arc furnaces to withstand extreme temperatures. Graphite Blocks are also used in parts of blast furnace linings where the high thermal conductivity of the graphite is critical. High-purity monolithics are often used as a continuous furnace lining instead of the carbon-magnesite bricks.

The US and European refractories industry had a crisis in 2000–2003, with an indifferent market for steel and a declining refractory consumption per tonne of steel underlying firm buyouts and many plant closings. Many of the plant closings resulted from the acquisition of Harbison-Walker Refractories by RHI AG some plants had their equipment auctioned off. Since much of the lost capacity was for carbon-magnesite brick, graphite consumption within refractories area moved towards alumina-graphite shapes and monolithics, and away from the brick.The major source of carbon-magnesite brick is now imports from China. Almost all of the above refractories are used to make steel and account for 75% of refractory consumption; the rest is used by a variety of industries, such as cement.
According to the USGS, US natural graphite consumption in refractories was 11,000 tonnes in 2006.

Steelmaking
Natural graphite in this end use mostly goes into carbon raising in molten steel, although it can be used to lubricate the dies used to extrude hot steel. Supplying carbon raisers is very competitive, therefore subject to cut-throat pricing from alternatives such as synthetic graphite powder, petroleum coke, and other forms of carbon. A carbon raiser is added to increase the carbon content of the steel to the specified level. An estimate based on USGS US graphite consumption statistics indicates that 10,500 tonnes were used in this fashion in 2005.

Expanded graphite

Expanded graphite is made by immersing natural flake graphite in a bath of chromic acid, then concentrated sulfuric acid, which forces the crystal lattice planes apart, thus expanding the graphite. The expanded graphite can be used to make graphite foil or used directly as "hot top" compound to insulate molten metal in a ladle or red-hot steel ingots and decrease heat loss, or as firestops fitted around a fire door or in sheet metal collars surrounding plastic pipe (during a fire, the graphite expands and chars to resist fire penetration and spread), or to make high-performance gasket material for high-temperature use. After being made into graphite foil, the foil is machined and assembled into the bipolar plates in fuel cells. The foil is made into heat sinks for laptop computers which keeps them cool while saving weight, and is made into a foil laminate that can be used in valve packings or made into gaskets. Old-style packings are now a minor member of this grouping: fine flake graphite in oils or greases for uses requiring heat resistance. A GAN estimate of current US natural graphite consumption in this end use is 7,500 tonnes.

Intercalated graphite
Main article: Graphite intercalation compound
Structure of CaC6
Graphite forms intercalation compounds with some metals and small molecules. In these compounds, the host molecule or atom gets "sandwiched" between the graphite layers, resulting in compounds with variable stoichiometry. A prominent example of an intercalation compound is potassium graphite, denoted by the formula KC8. Graphite intercalation compounds are superconductors. The highest transition temperature (by June 2009) Tc = 11.5 K is achieved in CaC6 and it further increases under applied pressure (15.1 K at 8 GPa).

Brake linings
Natural amorphous and fine flake graphite are used in brake linings or brake shoes for heavier (nonautomotive) vehicles, and became important with the need to substitute for asbestos. This use has been important for quite some time, but nonasbestos organic (NAO) compositions are beginning to cost graphite market share. A brake-lining industry shake-out with some plant closings has not helped either, nor has an indifferent automotive market. According to the USGS, US natural graphite consumption in brake linings was 6,510 tonnes in 2005.

Foundry facings and lubricants
A foundry facing mold wash is a water-based paint of amorphous or fine flake graphite. Painting the inside of a mold with it and letting it dry leaves a fine graphite coat that will ease separation of the object cast after the hot metal has cooled. Graphite lubricants are specialty items for use at very high or very low temperatures, as forging die lubricant, an antiseize agent, a gear lubricant for mining machinery, and to lubricate locks. Having low-grit graphite, or even better no-grit graphite (ultra high purity), is highly desirable. It can be used as a dry powder, in water or oil, or as colloidal graphite (a permanent suspension in a liquid). An estimate based on USGS graphite consumption statistics indicates that 2,200 tonnes was used in this fashion in 2005.[6]

Other uses
Natural graphite has found uses as the marking material ("lead") in common pencils, in zinc-carbon batteries, in electric motor brushes, and various specialized applications.