Synthetic Graphite
Graphite is a critical raw material used in electric vehicle (EV) battery production. With demand for EV and other batteries soaring, Bepex is working with suppliers to scale the production of synthetic graphite.
Helping Power the EV Revolution
EVs offer an eco-friendlier alternative to traditional vehicles. But EVs depend on batteries and batteries depend on graphite. Synthetic graphite offers performance and supply chain advantages compared to natural graphite. But traditional batch processing can’t keep pace with increasing demand. So Bepex is working with graphite suppliers to create continuous processing systems and improve the energy-intensive production process.
Faster Production. Better Returns.
Continuous processing leveraging Bepex equipment results in higher capacity and greatly reduced residence times compared in traditional batch processing. Replacing bulky, labor-intensive batch processes with compact, high-volume, continuous processing equipment also saves material-handling time, reduces floor space requirements, and cuts labor costs. That means lower operating costs and better cap ex returns.
More Control for Improved Product
Petroleum coke and pitch coke are carbon-rich byproducts of oil and coke refining processes. They are mixed with pitch, another carbon-rich byproduct, to produce the carbon feedstock used to create synthetic graphite. The Bepex Turbulizer high-shear, thin-film paddle mixer creates a homogeneous mixture of coke and pitch in seconds while its jacketed design provides the high temperatures required to ensure more consistent graphitization.
Experienced Partner for Next-Step Innovation
Many new products start with batch production. It makes sense – products are being fine-tuned and demand is limited and uncertain. But when it comes time to ramp up, engineers comfortable with batch processes often face a steep learning curve transforming manufacturing to continuous operations. That’s where Bepex steps in. We’re experts in continuous processing. Whether it’s a back-of envelope idea or a proven product ready to step-up to mass production, our Process Development Center is here to help analyze, develop, quantify and scale your products and processes.
Processing Innovation. Backed by Experience
Mixing/Blending
One of the first operations in the graphite production process is also one of the most vital. Mixing the petroleum coke with the pitch can be challenging given the material properties of each input. The Bepex Turbulizer high-shear, thin-film paddle mixer creates a homogeneous mixture of coke and pitch in seconds while its jacketed design provides the high temperatures required to ensure more consistent graphitization.
Heating/Cooling
Pre-heating the mixture prior to graphitization can provide operational and footprint savings, when done with a more efficient heating technology. Bepex has more than 100 years of experience in developing the most appropriate heating process using our wide range of technologies.
Turbulizer
The Turbulizer is built for near-instantaneous mixing or agglomeration of liquids and solids. Its high-speed rotor with adjustable paddles creates intense turbulence with short residence times to produce dust-free particles ranging in size from fine powders up to 2-3 mm.
Solidaire
The Solidaire thin layer paddle dryer offers the highest heat transfer coefficient available. Process dry or wet solids, liquids, slurries, cakes or pastes more efficiently, with more control, at lower cost. Solidaire applications include drying, devolatilizing, reacting, cooling, and crystallizing.
EV Innovation and More
Helping Pioneer Next-Gen Battery Production
At Bepex, we’re committed to helping customers develop new ingredients and components for their products.
Improved battery technology will play an important role in creating a more sustainable future.
Along with improving graphite production, we’re working with producers to extract and process battery-grade lithium more efficiently and with less energy consumption. Plus, we’re working with recyclers on developing equipment and processes to reclaim and reprocess materials from scrapped batteries.
It’s all part of our corporate commitment to creating equipment and processing solutions to help our customers create better products, more sustainably.
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Process Development
Feasibility
All new inquiries begin with a feasibility study. These studies aim to provide preliminary insights into the viability of a commercial process. Using as little as 100 grams of material, we can begin early process design, develop plans for pilot-testing and/or confirmation, and begin providing early economic estimates. Our experience across our wide range of technologies gives us a unique ability to provide quick feedback on the feasibility of your process.
Development
From our learnings, we’ll begin the process development work. The primary work in this phase takes place in the form of pilot-scale testing in our Process Development Center. Our pilot tests look a bit different than what you may have experienced in the past. Each test is designed to measure the system performance and feasibility rather than that of any single machine.
Each system is custom assembled for each test. Our goal is to provide as much of a pilot-scale simulation as possible while gathering scale-up data to deliver on commercial capacities. When a certain technology proves ineffective, we’ll draw from our range of options to determine if there is a better fit. The Process Development Center is our sandbox to build, test, and revise to ensure we get every detail right.
Budget Evaluation
With a successful pilot simulation completed, we now have everything we need to scale up and provide proposals for capital equipment with included performance guarantees.
System Design And Build
After receipt of the purchase order, we begin with both equipment and system engineering. Each proprietary technology we sell is custom-designed and built per application. We do not have any off-the-shelf units. At this stage, your exact system begins to take shape, including auxiliary equipment, process flow diagrams, process and instrumentation diagrams, safety provisions, and more.
Commissioning
After delivery and installation of your new system, Bepex will provide a mechanical check to ensure everything is placed according to plan. This is followed shortly thereafter by system commissioning. This is where our pilot-scale simulations become invaluable, as our team of application engineers, controls technicians, and sales engineers begin working with your team to successfully bring your system online.
Support
At this point, you’re up and running at rate, producing a quality product, but our work doesn’t stop there.
Following commissioning, Bepex remains a reliable partner, providing quality OEM parts, immediate field service, process optimization, training, system troubleshooting, and more. We have consistently had high customer retention rates, and we believe it is due in large part to our comprehensive approach to serving our customers long after the original sale.
Make Bepex Innovation Your Technical Advantage
Learn more about continuous synthetic graphite processing and our next-generation work in battery component development. Reach out to a Bepex processing expert.
