Graphite Development from a Manufacturers Perspective: Processing, Formation, and Benchmarking

Abstract

Graphite remains the most widely used anode material in lithium-ion batteries, and the initial formation of the solid electrolyte interphase (SEI) largely dictates the long-term performance of commercial cells. Developing a new graphite anode to diversify the supply chain remains challenging due to proprietary formation protocols and inconsistent test formats. In this study, we evaluate a pitch-coated synthetic graphite developed by James Durrans & Sons against a commercial benchmark using a harmonized methodology across a coin, three-electrode PAT cell, and pilot line built single-layer pouch cells. By standardizing electrode morphology, formation procedures, and testing conditions, we isolate the influence of active material properties, e.g., how the first cycle loss is linked to SEI formation and how coatings and cycling conditions such as temperature can influence it. Under "like for like"comparative studies of NMC 811//graphite pouch cell, the modified synthetic graphite developed displayed higher rate performance and increased capacity retention at 1C over 200 cycles over established commercial counterparts.