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Flake Graphite: Properties, Uses and Production Process

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Flake Graphite: Properties, Uses and Production Process

Properties It is a type of natural graphite that occurs as microscopic crystalline flakes. It has a flaky texture similar to mica or talc. The individual flakes are flat, thin and light with thickness ranging between 0.1 to 1.0 mm and diameters ranging from 10 to 300 microns. Due to its flaky structure, it can easily be separated into thin but light and flexible plates. It has some unique properties that make it suitable for various industrial applications. It has a high carbon content of around 95% which provides it a lubricating nature. It has a very high melting point of around 3,600°C which makes it heat resistant. It also has good electrical and thermal conductivity properties. Due to these combined properties, it finds extensive use as a dry lubricant and heat conductor. Uses Due to its flaky structure and excellent physico-chemical properties, it has wide applications in various industries: Lubrication: Finely grounded Flake graphite is used as a dry lubricant in machinery parts due to its excellent lubricating nature. It reduces friction between moving parts and prevents overheating and wear & tear. It is used as a lubricant in automobile engines, heavy machinery, and railroad brake shoes. Refractories: It is blended with clays to make graphite refractories due to its high-temperature stability. These refractories find use in the lining of furnaces in steel and other metal industries to withstand high temperatures. Battery Electrodes: Due to its lightweight, electrical conductivity, and stability, natural flake graphite is used as the anode material in lead-acid batteries, NiMH batteries, and lithium-ion batteries. It increases the efficiency and lifespan of batteries. Foundry Facings: Finely powdered graphite is mixed with no-bake phenolic resins to make foundry facing materials. These materials are applied on the inner surfaces of molds and cores in metal casting to impart a smooth finish to the cast metal parts. Pencils, Arts: It is processed and compressed into rods to make pencil leads due to its properties of smoothness, strength, and ability to produce dark lines. It is also used in painting and arts. Carbon Brushes: Finely powdered graphite is mixed with binders to produce carbon brushes used in electric motors for smooth current collection and transfer. Metallurgy: It powders find use in making electrodes used in arc welding, carbon arc lighting and electrothermic steelmaking furnaces. Nuclear Reactors: Due to its dimensional stability and ability to withstand high temperatures and radiation, it is used as a neutron moderator material in nuclear reactors. Production Process The production process of it involves mining and purification of the mineral precursor, followed by processing into usable forms: Mining: Natural flake graphite occurs mainly as veins in metamorphic schists and gneisses. It is mined by conventional underground or open-pit mining techniques based on the ore body geometry and thickness. The major producers are China, Brazil, North Korea, Canada and Madagascar. Purification: The mined ore is first crushed and ground to -200 mesh size. It is then floated in stages through sulfide and alkaline leaching to remove impurities like silicates and metal sulfides. Shaping: The purified graphite flake powder is formed into desired shapes by briquetting, extrusion or molding processes using binders. Rods, blocks, plates, sheets and discs are common production forms. Calcination: To enhance density, strength and resistivity, the shaped green compacts are heat treated at high temperatures up to 2500°C in a controlled atmosphere calciner. This process removes binders and densifies the final product. Graphitization: For higher conductivity applications, the needled calcined products are further heat treated at temperatures above 2500°C to induce crystallinity and anisotropy in the molecular structure through graphitization. This improves properties. Grading & Packaging: The processed flake graphite products are carefully sized, graded and packed based on specifications for downstream applications. Different mesh sizes are produced to suit various industrial needs. Quality Control: Rigorous quality control checks are carried out to ensure the processed flake graphite conforms to desired standards relating to purity, size, density, resistivity, strength and other key properties. Only the best quality passes for industrial use.


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About Author: Priya Pandey is a dynamic and passionate editor with over three years of expertise in content editing and proofreading. Holding a bachelor's degree in biotechnology, Priya has a knack for making the content engaging. Her diverse portfolio includes editing documents across different industries, including food and beverages, information and technology, healthcare, chemical and materials, etc. Priya's meticulous attention to detail and commitment to excellence make her an invaluable asset in the world of content creation and refinement.

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