Scientists at Perm Polytechnic University (PNRPU) have developed and patented a new method for producing thermally expanded graphite. When heated, the particles expand like popcorn, increasing in volume hundreds of times — the lighter the material, the better its quality.
The secret of the technology lies in a special plasma installation that creates a "barrel" with a temperature of 10,000 °C, which is twice as hot as the surface of the Sun. Graphite particles pass exactly through the center, instantly foaming up and turning into the lightest material without defects or losses. The yield of the finished product reaches 95%.
When processed with the new technology, the material weighs 1–1.8 grams — 2.5–10 times less than when using conventional plasma. Energy consumption has been reduced to 1.6 kWh per kilogram (like a household heater), whereas previously 98% of the energy was wasted.
The development will allow the creation of higher quality seals, thermal insulation and sorbents for aviation, the automotive industry, nuclear reactors and oil refining. The technology has already been patented and is ready for scaling.