Kentucky Researchers Turn Coal into High-Value Battery Material for Energy Storage

Researchers at the University of Kentucky are exploring a new pathway for clean energy storage by converting coal into battery-grade synthetic graphite, a key material used in lithium-ion batteries for electric vehicles, consumer electronics, and battery energy storage systems (BESS).

Led by Dr. Matthew Weisenberger at the University of Kentucky’s Center for Applied Energy Research (CAER), the team is developing a domestic and cost-competitive graphite source at a time when nearly 90% of global battery-grade graphite supply comes from China. With graphite making up a significant portion of lithium-ion batteries—an average EV battery requires roughly 165 pounds—the research could help strengthen U.S. battery supply chains while supporting energy storage growth.

The process combines coal with petroleum-derived materials to create highly pure synthetic graphite with a carbon purity level of 99.999%, suitable for advanced battery applications. Researchers have also demonstrated that blending coal into the production process can generate up to 39% more graphite compared with conventional petroleum-only feedstocks, improving both material yield and economic viability.

Beyond graphite production, the University’s integrated research infrastructure allows scientists to process raw coal, manufacture battery materials, assemble lithium-ion cells, and test battery performance within a single facility. This end-to-end capability is helping accelerate innovation in next-generation battery materials.

The research also aims to maximize resource utilization by extracting rare earth-rich mineral matter left behind during graphite production, creating additional high-value materials for advanced technologies.

As demand for grid-scale battery storage and EV batteries continues to rise globally, innovations such as coal-derived synthetic graphite could open new opportunities for cleaner domestic battery material production.