Synthetic Graphite vs Natural Graphite: A Comparison

Synthetic graphite production or natural deposits?

The main difference between synthetic graphite and its natural counterpart lies in how it is produced. While natural graphite is extracted as a naturally occurring mineral and then—depending on the required quality and intended application—processed, synthetic graphite is created via a technical manufacturing process. Producing synthetic graphite is based on an energy-intensive procedure: starting materials such as calcined petroleum coke (a by-product of oil refining) or other carbon materials are graphitised at temperatures above 2,000 °C. In this high-temperature process—the so-called graphitisation—the carbon atoms are realigned and converted into a crystalline structure until synthetic graphite is formed.

• Synthetic graphite production: Industrial manufacture through graphitisation at over 2,000 °C
• Natural graphite extraction: Obtained from deposits and then mechanically or chemically processed

Properties compared

At first glance, they appear almost identical: both natural and synthetic graphite display a dark grey to black colour—visually, the differences are hardly noticeable. They also have a similar general texture, at least on the surface. But what about their internal qualities?

Purity: Is synthetic graphite really superior?

Synthetic graphite is often described as the “purer” material—after all, it is made in a controlled, industrial process. But this view is too simplistic. For one, the production of synthetic graphite also relies on a product of natural origin that may be subject to fluctuations, namely petroleum. Furthermore, the natural alternative too can achieve impressively high purities. With modern processing technology, purity levels of up to 99.99% are possible—using a natural raw material. For many industrial applications that require the highest purity, natural graphite is therefore not only sufficient, but a genuine alternative to synthetic graphite.

Electrical & thermal conductivity: What both graphites can do

Both natural and synthetic graphite feature consistently high conductivity, both electrical and thermal. In a pure state, both materials achieve electrical conductivity in the range of 10³ to 10⁴ S/m—practically indistinguishable in day-to-day use. Their thermal conductivity is also comparable. When graphite is used as a filler in compounds, it’s mainly the filling grade, particle distribution and specific graphite type that determine the conductivity achieved—regardless of whether it’s synthetic or natural.

• Electrical conductivity: Both natural and synthetic graphite typically reach ranges of 10³ to 10⁴ S/m in pure form.
• Thermal conductivity: Both graphites have comparable thermal conductivity, resulting in no significant difference in performance.

Corrosion resistance: How robust are the graphites?

Graphite is generally considered resistant to corrosion, oxidation, and high temperatures. But there are differences between natural and synthetic graphite. The natural variety, due to its higher crystallinity, is inherently more resistant. This is because natural graphite crystallises over extremely long periods in nature, while the crystallisation of synthetic graphite occurs in a technically controlled manner over a few weeks.

And what about sustainability?

Natural and synthetic graphite differ greatly in terms of their environmental footprint. When it comes to sustainability, natural graphite usually comes out ahead, especially due to its much lower energy requirements. The main reason is the energy-intensive manufacturing process for synthetic graphite. The comparatively resource-friendly extraction of graphite results in a lower CO₂ footprint. More specifically:

• Natural graphite causes around 2 to 6 kg CO₂ per kilogram of graphite, depending on grade and processing.
• Synthetic graphite, in contrast, generates around 20 to 40 kg CO₂ per kilogram, depending on the energy source used.

Cost: a crucial factor

Which graphite is ultimately the better choice depends not only on technical requirements, but also on cost. Natural graphite is usually much more cost-effective, particularly for uses where extremely high purity is not required. In many cases, purities of 90 to 98% carbon are more than sufficient to ensure reliable and high-performance function. The remaining portion typically consists of aluminosilicates or similar mineral components that generally do not have a negative impact in most applications.

On the other hand, synthetic graphite production involves a much higher energy usage, which makes it noticeably more expensive, especially when produced on an industrial scale. There is also no option to manufacture synthetic graphite less pure, and therefore more cheaply, if purity is not essential.

Areas of application compared

Whether natural or synthetic graphite: which type is used depends greatly on the demands of each application. Synthetic graphite, for example, is particularly suitable for uses where graphite is needed in high purity as a shaped part. Natural graphite has a very broad range of applications, and is widely used in areas where the graphite’s properties are to be used in a particularly cost-effective way and/or where high purities are not required. Natural graphite is also especially suitable for applications requiring high resistance or corrosion resistance, as its high crystallinity makes it ideal for such purposes. In addition, the flame retardant additive expandable graphite can only be made from natural graphite.

There are, however, application areas—such as graphite for lithium-ion batteries or as a conductivity additive in plastics—where both natural and synthetic graphite can be used and each offers distinct advantages.

Typical applications for synthetic graphite:

• Electrodes for the steel industry
• Electronics and sensor systems
• Shaped parts for high-temperature technology

Typical applications for natural graphite:

• Lubricants and release agents
• Foundry products and refractory materials
• Pencil leads
• Thermal conductivity additive in cement
• Flame retardancy (as expandable graphite)

Conclusion: Who wins the graphite duel?

Both natural and synthetic graphite impress with a wide range of excellent properties—whether in terms of purity, resistance, cost, or adaptability for specific applications. Each has its right to exist, and for some uses, synthetic graphite is undoubtedly the right choice. If we take an overall view, though, we have a clear favourite: natural graphite. Why? Because, to us, natural graphite is more than just a raw material. It stands for taking responsibility, for uncompromising efficiency—and for a sustainable way to make materials powerful, safe, and fit for the future. Thanks to its natural origin, much lower energy requirements in processing, and broad field of application, it is not just an equal, but often the better choice for many uses—and thus the winner in a direct graphite comparison.

LUH – Your partner for natural graphite

As experienced specialists in industrial applications with natural graphite, we know what really matters. With over 90 years of expertise, an in-house certified quality laboratory, and a strong network of research and practice, we stand for more than just high-quality graphite products: We offer sound advice, technical expertise, and reliable support on a level playing field. Whether it’s halogen-free flame retardancy, high-performance fire protection systems, electrical or thermal conductivity, or lubricant applications—we assist you with tailored solutions based on this natural raw material.