Low‐Temperature Synthesis of Battery Grade Graphite: Mechanistic Insights, Electrochemical Performance, and Techno‐Economic Prospects

Abstract Graphite is an irreplaceable anode for Lithium‐ion batteries (LIBs) at status quo, and its demand will soar amid the supply chain and sustainability concerns of natural graphite (NG) and synthetic graphite (SG). Herein, LIB‐grade graphite is produced using a less energy‐intensive catalytic graphitization process. This work explores the catalytic graphite (CTG) growth mechanism, the impact of graphitization conditions on the degree of graphitization, aspects of developing high‐rate graphite anodes, upscaling strategies, and techno‐economic prospects. Operando thermal X‐ray diffractograms reveal that the CTG forms through carbon dissoluton in nickel and its subsequent segregation as graphite and nickel. CTG synthesized between 1100 and 1500 °C shows porous flaky morphology, with higher temperatures favoring superior graphitization and carbon purity. The growth of graphitic domains governs the electrochemical performance of CTG. CTG 1100 shows hard carbon‐like Li ⁺ ion storage, while CTG 1300 and CTG 1500 form graphite intercalation compounds owing to the larger graphitic crystallites. Pitch‐derived soft carbon coating onto CTG 1500 enhances its high‐rate capability compared to commercial graphite due to its intrinsic porosity. Improved electrochemical performance establishes CTG as a better alternative to NG and SG, and detailed techno‐economic analysis affirms its scalability prospects.