Natural graphite is mostly used for refractories, batteries, steelmaking, expanded graphite, brake linings, foundry facings, and lubricants. where the high thermal conductivity of the graphite is critical to ensuring adequate cooling of the bottom and hearth of the furnace. High-purity monolithics are often used as a continuous furnace lining instead of 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 closures. Many of the plant closures resulted from the acquisition of Harbison-Walker Refractories by
RHI AG and some plants had their equipment auctioned off. Since much of the lost capacity was for carbon-magnesite brick, graphite consumption within the refractories area moved towards alumina-graphite shapes and Monolithics, and away from the brick. The major source of carbon-magnesite brick is now 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 comprised 12,500 tonnes in 2010. Graphite is the "predominant anode material used today in lithium-ion batteries". Electric-vehicle (EV) batteries contain four basic components: anode, cathode, electrolyte, and separator. While there is much focus on the cathode materialslithium, nickel, cobalt, manganese, etc., the anode material used in virtually all EV batteries is graphite. The demand for batteries, primarily
nickel–metal hydride and
lithium-ion batteries, caused a growth in demand for graphite in the late 1980s and early 1990s – a growth driven by portable electronics, such as portable
CD players and
power tools.
Laptops,
mobile phones,
tablets, and smartphone products have increased the demand for batteries. Electric-vehicle batteries are anticipated to increase graphite demand. As an example, a lithium-ion battery in a fully electric
Nissan Leaf contains nearly 40 kg of graphite. Radioactive graphite removed from nuclear reactors has been investigated as a source of electricity for low-power applications. This waste is rich in
carbon-14, which emits electrons through
beta decay, so it could potentially be used as the basis for a
betavoltaic device. This concept is known as the
diamond battery.
Steelmaking Natural graphite in
steelmaking mostly goes into raising the carbon content in molten steel; it can also serve to lubricate the dies used to extrude hot steel. Carbon additives face competitive 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 a specified level. An estimate based on
USGS's graphite consumption statistics indicates that
steelmakers in the US used 10,500 tonnes in this fashion in 2005.
Everyday use Pencils The ability to leave marks on paper and other objects gave graphite its name, given in 1789 by German mineralogist
Abraham Gottlob Werner. It stems from
γράφειν ("graphein"), meaning
to write or
draw in
Ancient Greek. From the 16th century, all pencils were made with leads of English natural graphite, but modern pencil lead is most commonly a mix of powdered graphite and clay; it was invented by
Nicolas-Jacques Conté in 1795. It is chemically unrelated to the metal
lead, whose ores had a similar appearance, hence the continuation of the name.
Plumbago is another older term for natural graphite used for
drawing, typically as a lump of the mineral without a wood casing. The term
plumbago drawing is normally restricted to 17th and 18th-century works, mostly portraits. Today, pencils are still a small but significant market for natural graphite. Around 7% of the 1.1 million tonnes produced in 2011 was used to make pencils. Low-quality amorphous graphite is used and sourced mainly from China. Graphite of various hardness or softness results in different qualities and tones when used as an
artistic medium.
Pinewood derby Graphite is probably the most-used lubricant in
pinewood derbies.
Other uses Natural graphite has found uses in
zinc-carbon batteries,
electric motor brushes, and various specialized applications. Railroads would often mix powdered graphite with
waste oil or linseed oil to create a heat-resistant protective coating for the exposed portions of a steam locomotive's boiler, such as the
smokebox or lower part of the
firebox. The
Scope soldering iron uses a graphite tip as its heating element.
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 a "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. Graphite's ability to intercalate lithium ions without significant damage from swelling is what makes it the dominant anode material in lithium-ion batteries. ==Mining, beneficiation, and milling==