By: Crystal Carter
Featured Inventor: Micah Green
A new technology developed at Texas A&M University is set to transform the way synthetic graphite is produced—cutting costs, reducing carbon emissions, and making high-purity graphite more accessible for critical industries. Dr. Micah Green, a Gas Processors Suppliers Association Professor in the Artie McFerrin Department of Chemical Engineering,
along with Associate Professor Dr. Faruque Hasan and the National Energy Technology Laboratory, has pioneered a low-temperature catalytic graphitization process that converts fuel-grade petroleum coke into pure synthetic graphite using an iron-based catalyst.
This innovation significantly reduces the carbon footprint of graphite production, lowering the processing temperature from 3000°C over several days to just 1400°C in 2-3 hours. By bypassing the energy-intensive steps of conventional processes, this catalytic graphitization method offers a more sustainable and cost-effective solution for producing graphite—a critical material in lithium-ion batteries, electric arc furnaces, advanced electronics, concrete, and nuclear energy.
Why Graphite Matters: Powering the Future
Graphite has gained prominence as an essential material in modern energy and industrial applications. It serves as the anode material in lithium-ion batteries, powering electric vehicles (EVs) and renewable energy storage solutions. It is also used in electric arc furnaces for steel production, enabling sustainable recycling of metals. Furthermore, its thermal and electrical conductivity make it indispensable in electronics, concrete, and nuclear energy applications. However, producing pure synthetic graphite is costly and carbon-intensive. Current methods require several days at extreme temperatures of 3000°C, consuming vast amounts of energy and generating significant emissions. Dr. Green’s catalytic graphitization breakthrough offers a game-changing alternative—transforming a low-value refinery byproduct into a high-value material using less energy and fewer emissions.
Texas A&M’s Commitment to Real-World Impact
Dr. Green’s innovative technology exemplifies The Texas A&M University System’s mission of leveraging research to address real-world challenges. His team’s discovery aligns with global efforts to decarbonize industrial processes, improve materials sustainability, and support the transition to cleaner energy solutions.
By creating a pathway to convert lower-grade petroleum coke—a carbon byproduct of oil refining—into valuable synthetic graphite, this research not only reduces waste and emissions but also provides a domestic supply of high-purity graphite, reducing reliance on imported materials.
The Future of Innovation: What Excites Dr. Green
For Dr. Green, the future of innovation lies in bridging fundamental research and industrial application—a process that Texas A&M fosters.
“One thing that I have enjoyed at Texas A&M is the ability for fundamental materials research in the lab to transition to industry use,” says Dr. Green. “This is especially true in a dynamic state like Texas, where both large and small companies have been investing heavily in new materials development. I am particularly glad to see the petrochemical industry engaging with moves to recover carbon as valuable new materials, rather than as emissions.”
This shift toward sustainability in industrial sectors is crucial for reducing carbon footprints while maintaining economic viability. The petrochemical industry’s interest in carbon recovery aligns with the broader global push for circular economy solutions—where waste materials are repurposed for new, high-value applications.
Dr. Green’s 5-Year Goals: Electrifying Industrial Processes
Looking ahead, Dr. Green and his team (Green Lab) are focused on electrifying industrial heating processes to enhance sustainability across multiple applications.
“My group is interested in bringing electrification of heating to a variety of industrial processes, including additive manufacturing of polymers and composites, as well as heated chemical reactors,” Dr. Green explains.
His research will also continue to focus on collaborating with industry partners to redirect petrochemical streams from emissions toward valuable carbon materials. This approach aligns with broader sustainability goals, ensuring that industrial byproducts are transformed into useful and high-performance materials. Dr. Green’s work in catalytic graphitization represents a breakthrough in materials science—offering a low-cost, low-carbon method for producing synthetic graphite at scale.
