Properties and Qualities of Our synthetic Carbon

The solid carbon produced during methane plasma pyrolysis is far more than a byproduct: it is a high-quality functional material with versatile application potential. Here we present what makes it special – scientifically detailed for professionals and clearly explained for users, investors, and partners. To further explore and develop these applications, we are working closely with our cooperation partner RAG Austria AG in the field of commercial carbon utilization. Together, we are investigating a wide range of properties and use cases for this solid carbon – from industrial applications to long-term carbon storage solutions

Chemical Purity

Technical:

• XRF analysis shows a carbon content of 99.9%.
• Metallic impurities are in the ppm range (e.g., Fe ~0.007%, Al <0.01%).
• Moisture content: very low (0.52–1.09%)
• Volatile matter (V.M): low (1.79–2.03%)
• Ash content: negligibly low (only 0.02–0.31%)
• Fixed carbon: very high (96.82–97.43%)

Summary: Our carbon consists almost entirely of pure carbon. Moisture, ash, and volatile substances are extremely low – a quality marker for high-performance technical applications like batteries, filters, or composites.

Bulk Density & Calorific Value

Technical:

• Tap density of plasma carbon samples (GF08B, GF6B, GF8B): 0.26 g/ml
• Reference (N990 CB): 0.77 g/ml
• Calorific value: ~8,000 cal/g (Plasma carbon), 8,112 cal/g (N990 CB)

Summary: Our carbon is very fluffy and lightweight, which is advantageous in applications requiring low weight and high surface area. At the same time, it has a high calorific value, comparable to standard carbon black.

Structure & Morphology

Technical:

• SEM and TEM images reveal amorphous clusters, 2D nanosheets, and fibrous structures.
• XRD analysis: broad, weak (002) peaks confirm amorphous nature.

Summary: The simultaneous presence of amorphous, fibrous, and nanosheet-like carbon from a single process (plasma pyrolysis) is exceptional and enables:

• Use in batteries and supercapacitors (due to 2D structures)
• Application in filters or catalyst supports (thanks to high surface area)
• Potential for conductive composites (via fiber and amorphous carbon mix; electrodes)

Pore Structure & Surface Area

Technical:

• BET surface area: 32–38 m²/g
• Pore distribution: combined micro- and mesopores, average ~5 nm
• Type V isotherm: low nitrogen affinity, no hysteresis

The carbon has a fine, uniform pore structure (comprising both micro- and mesopores), which is ideal for applications such as battery materials or filtration systems.

Its specific surface area is around 30–38 m²/g – significantly higher than conventional industrial carbon black, yet achieved without costly activation processes.

The pores are functionally accessible but not overly developed, making the carbon easy to dose and highly versatile, suitable for use in plastics, rubber, paints, or catalysts.

Summary: Materials with balanced pore structures are in high demand across emerging markets – for example in energy storage, lightweight composites, and CO₂ filtration solutions. Unlike activated carbon, our carbon does not excessively bind gas, making it easier to handle and more cost-efficient during processing. We combine industrial relevance with sustainability: our solid carbon byproduct is valuable, not waste.

Electrical Conductivity

Technical:

• Conductivity: 4–6 S/m under 1,200 kgf pressure - The more the carbon is compressed, the better it conducts electricity.
• Resistance decreases with compaction → good contact conductivity

Summary: The carbon produced via methane plasma pyrolysis is electrically conductive, especially when compacted – making it ideal for applications such as:

• Conductive plastics (e.g. ESD protection, antistatic housings)
• Rubber compounds for sensors
• Electrode materials

While it does not reach the conductivity levels of highly graphitized carbon, it offers a strong balance of conductivity, structure, and sustainability – all at a cost-efficient production scale.

Thermal Stability

Technical:

• TGA in N2: stable up to >800°C, max. weight loss 2.3%
• In air: combustion begins at ~650°C

Summary: The carbon remains stable even at high temperatures. Without oxygen, it hardly decomposes. In air, it can be used as a fuel or thermally processed.

Oil Absorption Number (OAN)

Graforce carbon has an Oil Absorption Number (OAN) of ~72–74 mL/100g, roughly double that of a reference N990 carbon black (∼33 mL). A higher OAN indicates a more structured, aggregate-rich carbon that can absorb more liquid. In practical terms, this means our carbon mixes extremely well with oils, polymers, and binders, ensuring uniform distribution in rubber compounds, plastics, inks, or concrete admixtures.

Technical:

• OAN values: 72–74 ml/100 g (N990 reference: 33 ml)
• Indicates high structure and dispersibility

Summary: Our carbon absorbs oils and binders extremely well. This is a sign of excellent mixability in rubber, paints, or plastics.

 Comparison with Conventional Carbon (e.g. N990)

Technical:

• Compared to N990 CB: higher OAN (approx. 2x), equal or better thermal stability, finer pore structure.
• Outperforms traditional furnace black in structural and dispersion properties.

Summary: Compared to conventional industrial carbon black, our carbon is finer, more structured, and higher performing – with the added benefit of a significantly lower carbon footprint.

Sustainability & CO2 Benefits

Technical:

• CO2 savings compared to fossil-based carbon: up to 5.5 tons of CO2 per ton of carbon (vs. petcoke-based black).
• No pre- or post-treatment required, low energy demand thanks to plasma process.

Summary: Our carbon is not only technically strong but also climate-positive: every ton produced avoids CO2 compared to conventional alternatives.

Evaluation of Particle Stability of Graforce Carbon for Chlorination Processes

To assess the suitability of our solid carbon in thermochemical chlorination, a physical strength and abrasion test was conducted. The objective was to determine whether the material maintains its structural integrity during handling and whether the resulting particle size distribution is compatible with typical process requirements.

Key Findings:

• The tested carbon showed a particle size distribution below 500 µm that is comparable to several industrial carbon materials.
• With a fine fraction of approximately 3–4 %, the material falls within the industry-accepted range and demonstrates no excessive abrasion during preparation.
• In comparison, other tested carbon grades showed higher fine fractions of up to 7%, which may reduce residence time in the reactor and affect conversion efficiency.
• The ultrafine portion (<50 µm) was low across all samples – a favorable indicator for reactor stability and performance.

Test Conditions (Excerpt):

• The carbon material was used at an 18% mass fraction relative to total dry mass.
• The results were benchmarked against physically processed industrial carbon references, including high-grade calcined materials.

Summary: In this initial screening, our carbon demonstrated sufficient mechanical stability and a favorable fine particle profile. The results indicate that it can be considered suitable for chlorination processes, particularly with regard to process compatibility and operational stability.

 Pelletized Carbon – Optimized for Industrial Handling and Performance

In addition to its chemical purity and electrical conductivity, our carbon stands out for its physical adaptability. For many industrial applications – in metallurgy, chemicals, energy, or environmental technologies – not only the composition but also the handling form of the material is essential. That’s why we’ve successfully developed multiple pelletization methods for our plasma pyrolysis carbon.

Starting Point: Fine Dispersed Powder

The raw material is supplied as a fine, free-flowing powder with a particle size distribution mainly between 0.5 and 10 µm (see Figures 1 & 2). This fine structure offers a very high specific surface area – ideal for adsorption or catalytic use. However, the powder form presents challenges in large-scale processing due to dust generation, dosing inconsistency, and reduced reactor residence time.

Dry Mechanical Pelletization (No Additives)

Through purely mechanical compaction – without chemical binders – we formed pellets with diameters of approx. 0.8–1.2 mm. Particle size analysis confirms a narrow grain size distribution in the millimeter range, ideal for bulk handling and uniform reactor performance.

✔ No binders – 100% pure carbon
✔ Minimal fines generation
✔ High thermal and mechanical stability
✔ Easy to store, transport, and dose

 Water-Assisted Pelletization

To enhance granule formation, we also tested water-based pelletization. By adjusting the water content, we were able to influence pellet consistency without introducing foreign substances.

Depending on the process requirements, pellet strength and moisture can be adjusted accordingly – from flowable to form-stable.

Benefits for Industrial Processes

• Dust-free handling for logistics and operations
• Improved dosing behavior in reactors and continuous systems
• Stable residence times, essential for chlorination and pyrolysis
• Scalable & binder-free – preserves carbon purity
• Customizable pellet strength via moisture control