Pulickel Ajayan, Benjamin M. Professor of Engineering at Rice University, along with research scientist Sohini Bhattacharyya, has outlined a new perspective on the future of graphite supply chains and sustainability. The team presents strategies aimed at reducing the environmental footprint of graphite production while improving supply resilience.
Bhattacharyya, S., Roy, S., Lin, X., Campagnol, N., Vlad, A., & Ajayan, P. M. (2025). Graphite: the new critical mineral. Nature Reviews Materials. https://doi.org/10.1038/s41578-025-00848-5
Graphite, once regarded as a simple industrial commodity, has now become a cornerstone of modern clean energy technologies. As the main anode material in lithium-ion batteries, its demand is rising sharply alongside the expansion of electric vehicles and energy storage systems. However, despite growing global need, production remains concentrated in a few regions and is still heavily carbon intensive.
Current graphite supply chains are dominated by a small number of producers, particularly in refining and processing stages, which exposes markets to geopolitical risks and potential shortages. Synthetic graphite, often made from petroleum-based materials, contributes significantly to emissions, undermining the overall goal of decarbonising the energy transition. Demand projections indicate that by 2030, the need for battery-grade graphite could be four times higher than current production levels, underscoring the urgency of developing more sustainable methods.
The Rice University perspective explores several promising paths forward. One focus is the production of synthetic graphite from renewable feedstocks such as biomass or from carbon captured directly from industrial emissions. Another is the recycling of graphite from spent lithium-ion batteries to reduce dependence on raw material extraction. The researchers also highlight the importance of diversifying supply chains geographically to reduce reliance on a few dominant nations and encourage regional processing capacity.
Equally critical is the need to lower the carbon intensity of manufacturing processes. This includes reengineering purification and spheroidisation techniques to reduce energy consumption and chemical waste. The authors emphasise that a combination of clean production, recycling, and decentralised supply systems could transform graphite from a vulnerability in the energy transition to a stable and sustainable resource.
Other research groups have echoed these concerns. Independent analyses show that while graphite reserves are adequate, the concentration of refining capacity creates systemic risk. Companies across North America, Europe, and Asia are beginning to form vertically integrated supply networks aimed at reducing reliance on traditional sources. The industrial shift is already underway, as new facilities explore low-carbon processing routes and partnerships to build an ex-China supply chain for graphite materials.
For engineers and materials scientists, the implications are substantial. Lower-carbon production methods will require rethinking process design from the ground up, exploring alternative feedstocks, and integrating recycling infrastructure into existing battery production lines. There is also growing pressure to improve traceability in the graphite supply chain, ensuring manufacturers can account for both the origin and environmental impact of their inputs.
From a policy standpoint, aligning engineering innovation with incentives such as tax credits and sustainable procurement standards could accelerate progress. Regional governments that prioritise clean energy and stable regulation may become new hubs for graphite processing and recycling industries.
Despite the optimism, challenges remain. Scaling renewable or recycled graphite production to meet future demand will take significant time and investment. Technical questions persist about whether recovered or bio-based graphite can consistently meet the performance standards required for high-capacity, fast-charging batteries. Furthermore, as the supply network evolves, avoiding the replication of the same opaque and carbon-heavy structures that define current graphite markets will require careful oversight.
Graphite’s status has changed from an overlooked commodity to a strategic material central to clean energy systems. The work led by Pulickel Ajayan and Sohini Bhattacharyya underscores that the technology to make its production cleaner and more resilient is within reach—but realising that vision will depend on engineering innovation, international cooperation, and forward-thinking industrial policy.
Adrian graduated with a Masters Degree (1st Class Honours) in Chemical Engineering from Chester University along with Harris. His master’s research aimed to develop a standardadised clean water oxygenation transfer procedure to test bubble diffusers that are currently used in the wastewater industry commercial market. He has also undergone placments in both US and China primarely focused within the R&D department and is an associate member of the Institute of Chemical Engineers (IChemE).
