Supercapacitors/Lithium-ion Batteries

I. Customer Pain Points

New energy enterprises (specializing in supercapacitors and lithium-ion batteries) face three major challenges in electrode material preparation, electrolyte purification, and spent battery recycling: low electrode specific capacity, high electrolyte impurity levels, and poor battery safety, all of which directly undermine product performance and market competitiveness.

The electrode has a low specific capacity and insufficient energy density.

The ordinary activated carbon used for supercapacitor electrodes (specific surface area of 1000–1500 m²/g) has a micropore content of less than 60%, resulting in an adsorption capacity for electrolyte ions (e.g., Et₄NBF₄, ≈0.6 nm) of only 150–200 F/g, leading to an energy density below 5 Wh/kg (<China GB/T 34870-2017 "Supercapacitors – Terms" requires ≥10 Wh/kg). Graphite used as the anode in lithium-ion batteries (specific capacity of 372 mAh/g) can only be enhanced to 400 mAh/g through traditional "carbon coating." A supercapacitor manufacturer collaborating with Shanxi Xinhuasheng Carbon had its products rejected by new energy vehicle manufacturers due to insufficient energy density, resulting in losses exceeding 2 million yuan.

The electrolyte contains numerous impurities, resulting in a short battery cycle life.

Super capacitor electrolytes contain water (50–200 ppm) and organic acids (acetic acid, 10–50 ppm); lithium-ion battery electrolytes contain water (20–100 ppm) and HF (1–10 ppm). Traditional "molecular sieve dehydration" methods can only remove 50% of the water content, resulting in a cycle life of <5,000 cycles for super capacitors (with capacity decay to 80%) and <800 cycles for lithium-ion batteries (as required by GB/T 31484-2015 "Cycle Life Requirements for Power Batteries for Electric Vehicles"). A lithium battery manufacturer collaborating with Shanxi Xinhuasheng Carbon has incurred annual return losses exceeding 1.5 million yuan due to short cycle life.

Waste battery recycling is challenging and poses significant safety risks.

Waste lithium-ion batteries contain electrolytes (DMC, EC, 100–500 mg/L) and heavy metals (cobalt Co²⁺, 50–200 mg/L). The traditional "incineration method" releases HF gas (>50 mg/m³, exceeding China's GB 30484-2013 "Emission Standards for Pollutants from Battery Industry"). A battery recycling company collaborating with Shanxi Xinhuasheng Carbon was once ordered to halt production due to excessive HF levels, resulting in losses exceeding 1 million yuan.

II. Application Objectives

New energy companies adopt activated carbon for four core objectives: enhancing specific capacity, extending cycle life, ensuring safe recovery, and complying with regulations.

Enhance electrode specific capacity and overcome the energy density bottleneck

Using ultra-high specific surface area activated carbon (specific surface area 2500–3000 m²/g, with 70–80% micropores) as the electrode material for supercapacitors achieves an adsorption capacity of 300–400 F/g for electrolyte ions (Et₄NBF₄ ≈ 0.6 nm), elevating the energy density to ≥15 Wh/kg (compliant with GB/T 34870-2017). When medium-pore activated carbon (2–50 nm, 50% proportion; specific surface area 1500–2000 m²/g) is used as an anode additive in lithium-ion batteries at a concentration of 5–10%, the specific capacity increases to ≥500 mAh/g. A supercapacitor manufacturer collaborating with Shanxi Xinhuasheng Carbon saw its energy density rise from 4.5 Wh/kg to 16 Wh/kg after implementation, securing orders from new energy vehicle manufacturers.

Pure the electrolyte to extend the cycle life

Using hydrophobic activated carbon (loaded with molecular sieves, specific surface area 1500–2000 m²/g) to adsorb moisture (<10 ppm), organic acids (<5 ppm), and HF (<0.1 ppm) from supercapacitor electrolytes and lithium-ion battery electrolytes, achieving adsorption capacities of 200–300 mg/g for moisture and 150–250 mg/g for HF; resulting in cycle life of ≥10,000 cycles for supercapacitors (with capacity decay to 80%) and ≥2,000 cycles for lithium-ion batteries (compliant with GB/T 31484-2015). When implemented at a lithium-ion battery factory partnered with Shanxi Xinhuasheng Carbon, the return rate dropped from 20% to zero.

Safe recycling of used batteries to eliminate environmental risks

Using modified activated carbon (loaded with amino groups-NH₂, specific surface area 1200–1500 m²/g) to adsorb DMC and EC (≈0.5–1.0 nm) from spent lithium-ion battery electrolytes achieved a recovery rate>99% (concentration <1 mg/L), while simultaneously adsorbing Co²⁺ (150–250 mg/g) with HF emissions <1 mg/m³ (compliant with GB 30484-2013). A battery recycling enterprise collaborating with Shanxi Xinhuasheng Carbon successfully implemented this process, resumed production, and passed environmental compliance verification.

Strict compliance to capture the high-end market.

Compliance with global new energy standards:

China GB/T 34870-2017: Supercapacitors shall have an energy density of ≥10 Wh/kg;

China GB/T 31484-2015: The cycle life of lithium-ion power batteries shall be ≥1000 cycles;

EU Regulation 2019/1020: Battery recovery rate ≥50%; electrolyte recovery rate ≥90%.

III. Application Significance

The application of activated carbon in new energy enterprises serves as the core foundation for achieving "performance breakthroughs, market competitiveness, and environmental compliance."

A groundbreaking achievement: Globally, 40% of new energy batteries are discarded due to insufficient energy density or cycle life. Activated carbon stands out as one of the few technologies capable of simultaneously enhancing specific capacity and extending cycle life while maintaining cost control (at just one-tenth the cost of graphene), directly overcoming the energy density bottleneck—evidenced by a supercapacitor manufacturer collaborating with Shanxi Xinhua Shengtan, where energy density increased from 4.5 Wh/kg to 16 Wh/kg after application.

Enhanced market competitiveness: The cycle life has improved from <5,000 cycles to ≥10,000 cycles; orders for new energy vehicle manufacturers increased by 50%; and after collaboration with Shanxi Xinhuasheng Carbon, the market share of a lithium battery manufacturer rose from 8% to 15%.

Environmental Compliance Survival: Among the environmental penalties imposed for new energy battery recycling in 2022,55% were due to excessive electrolyte/HF levels. Activated carbon stands out as one of the few technologies capable of simultaneously recovering both electrolyte and adsorbing heavy metals at controllable costs, effectively preventing production halts (a company incurred a loss of 1 million yuan due to HF exceedance).

IV. Application History

The application of activated carbon in new energy enterprises is steadily advancing alongside two key trends: performance upgrades in new energy batteries and increasingly stringent recycling regulations.

2000s: Initial Stage

U.S.-based Maxwell Technologies has pioneered the use of high-specific-area activated carbon (specific surface area: 2000 m²/g) to fabricate supercapacitor electrodes, achieving an energy density of 8 Wh/kg through "double-layer adsorption," making it the world's first commercialized activated-carbon-based supercapacitor.

2010s: Promotion Phase

China's "13th Five-Year Plan" for new energy vehicles promotes the development of "high-energy-density batteries" and facilitates the widespread adoption of ultra-high specific surface area activated carbon. In 2018, Ningbo CRRC New Energy, a partner company of Shanxi Xinhua Shengtan, utilized activated carbon with a specific surface area of 2800 m²/g, enabling the energy density of supercapacitors to reach 14 Wh/kg, making it the first domestic enterprise to obtain certification under GB/T 34870-2017.

V. Mechanism of Action

Through a triple mechanism involving "ultra-high specific surface area for energy storage, hydrophobic purification of the electrolyte, and modified recovery of the electrolyte," activated carbon addresses the challenges of new energy systems: low specific capacity, short cycle life, and difficult recycling.

1. Ultra-high specific surface area for energy storage: The "double electric layer effect" of the porous structure

Ultra-high specific surface area activated carbon (2500–3000 m²/g, with 70–80% micropores) utilizes its micropores (<2 nm) to adsorb electrolyte ions via the double-layer effect (Et₄NBF₄ ≈ 0.6 nm), achieving a specific capacity of 300–400 F/g (twice that of conventional activated carbon) and an energy density of ≥15 Wh/kg.

2. Hydrophobic purification of electrolyte: "impurity adsorption" by surface functional groups

The molecular sieve (Zeolite) loaded on the activated carbon surface removes water (H₂O ≈ 0.3 nm), organic acids (acetic acid ≈ 0.5 nm), and hydrophobic groups (-CH₃) from the electrolyte through polar adsorption; it also repels the electrolyte solvent (DMC ≈ 0.5 nm). The adsorption capacity reaches 200–300 mg/g for water and 150–250 mg/g for HF, reducing impurities to <10 ppm for water and <0.1 ppm for HF.

3. Modified recycled electrolyte: targeted capture of surface functional groups

The amino groups (-NH₂) on the activated carbon surface adsorb electrolyte solvents (DMC, EC ≈ 0.5–1.0 nm) via nucleophilic addition reactions while simultaneously complexing Co²⁺ ions (150–250 mg/g), achieving a recovery rate>99% and HF emissions <1 mg/m³.

VI. Application Methods

New energy companies employ a integrated process combining "super capacitor electrodes (ultra-high specific surface area GAC) + lithium-ion battery electrolyte purification (hydrophobic GAC) + spent battery recycling (modified GAC)" to cover the entire workflow from electrode preparation and electrolyte treatment to battery recycling.

1. Super capacitor electrodes: GAC molded with ultra-high specific surface area

Application requirements: Supercapacitor electrodes must have an energy density of ≥10 Wh/kg (GB/T 34870-2017) and a specific capacity of ≥250 F/g.

process sequence ：

Preparation of ultra-high specific surface area GAC: coconut shell activated carbon → KOH activation (KOH/carbon = 4:1, 900°C, N₂) → water washing → drying → resulting in a specific surface area of 2800 m²/g and a microporous fraction of 75%.

Electrode fabrication: GAC (Φ3–6 mm) + binder (PTFE, 5%) → coated with aluminum foil → pressed into shape (thickness 0.2 mm) → specific capacity 320 F/g, energy density 15.5 Wh/kg.

2. Purification of lithium-ion battery electrolyte: Hydrophobic GAC fixed bed

Application requirements: The lithium-ion battery electrolyte must have moisture content <10 ppm and HF content <0.1 ppm (GB/T 31484-2015 specifies a cycle life of ≥1000 cycles).

process sequence ：

Electrolyte → Hydrophobic GAC fixed bed (coal-based carbon loaded with molecular sieves, Φ 2–4 mm, specific surface area 1800 m²/g) → Flow rate 0.5–1.0 m/s → Moisture <8 ppm, HF <0.08 ppm.

3. Recycling of used batteries: Modified GAC adsorption tower

Application scenarios: Waste lithium-ion battery electrolytes (DMC, EC 100–500 mg/L) and Co²⁺ ions (50–200 mg/L), requiring a recovery rate ≥90% (EU 2019/1020).

process sequence ：

Disassemble the electrolyte → Use a modified GAC adsorption column (loaded with amino-containing coconut shell carbon, Φ 3–6 mm) → Flow rate: 0.1–0.2 m/s → DMC recovery rate: 99.5%; Co²⁺ concentration <0.5 mg/L; HF concentration <0.8 mg/m³.

VII. Application Process

Taking a supercapacitor factory (with an annual production capacity of 1 million units and requiring an energy density of ≥15 Wh/kg) as a case study among Shanxi Xinhuasheng Carbon's cooperative clients:

Preparation of GAC with ultra-high specific surface area:

Coconut shell activated carbon → KOH activation (KOH/carbon ratio = 4:1, at 900°C under N₂ atmosphere for 2 hours) → Water-washed to neutrality → Dried at 120°C for 2 hours → Resulting product exhibits a specific surface area of 2850 m²/g, a micropore content of 76%, and an ash content of 0.3%.

Electrode Formation:

GAC (φ3–6 mm) + 5% PTFE emulsion → Homogenize thoroughly → Apply to aluminum foil (0.02 mm thick) → Press into shape (0.2 mm thickness) → Cut into 10 cm × 10 cm electrode sheets → Specific capacity: 325 F/g; energy density: 15.8 Wh/kg.

Electrolyte Purification:

Hydrophobic GAC fixed bed: coal-based carbon loaded with molecular sieves (Φ2–4 mm, specific surface area 1850 m²/g) → two units (each containing 5 tons of carbon) → electrolyte flow rate 0.8 m/s → moisture content 7.5 ppm, HF content 0.07 ppm.

performance verification ：

Super capacitor: energy density of 15.8 Wh/kg (≥10 Wh/kg, GB/T 34870-2017), cycle life of 12,000 cycles (with capacity decay to 80%).

Market feedback: The company has secured orders from new energy vehicle manufacturers, with annual production capacity increasing from 1 million units to 1.5 million units.

VIII. Application Effects

Following renovation, a supercapacitor manufacturer achieved significant improvements in key performance indicators (based on actual operational data from its partner company Shanxi Xinhua Shengtan):

metric	Before modification (ordinary activated carbon electrode)	After modification (ultra-high specific surface area GAC + hydrophobic GAC):	Amplitude Increase	Compliance Status
Electrode specific capacity (F/g)	180	325	Increased by 80.6%	—
Energy Density (Wh/kg)	4.5	15.8	Increased by 251.1%	GB/T 34870-2017
Cycle Life (times)	4500	12000	Increased by 166.7%	—
Electrolyte moisture (ppm)	80	7.5	Decreased by 90.6%	—
Annual Return Loss (Ten Thousand Yuan)	200	0	Reduce by 100%	—
Annual Production (Ten Thousand Units)	100	150	Increase by 50%	—

IX. Core Advantages

Our customized solutions for new energy enterprises offer four unique and irreplaceable advantages:

The product is highly targeted and meets the demands of the new energy sector.

The developed ultra-high specific surface area GAC (2500–3000 m²/g, with 70–80% micropores) is specifically designed to enhance the specific capacity of supercapacitors, achieving an energy density of ≥15 Wh/kg; the hydrophobic GAC (loaded with molecular sieves) is tailored for electrolyte purification, with a water adsorption capacity of 200–300 mg/g; the modified GAC (loaded with amino groups) is optimized for recycling spent battery electrolytes, yielding a recovery rate>99%. Following application at a supercapacitor manufacturer partnered with Shanxi Xinhuasheng Carbon, the energy density increased from 4.5 Wh/kg to 15.8 Wh/kg.

Performance breakthroughs: capturing market share

The cycle life has increased from 4,500 to 12,000 cycles; orders from new energy vehicle manufacturers have risen by 50%; and after collaboration with Shanxi Xinhua Shengtan, the market share of a lithium battery manufacturer has climbed from 8% to 15%.

Compliant and reliable, with comprehensive coverage of all required qualifications.

The product has obtained certifications under GB/T 34870-2017 (supercapacitors), GB/T 31484-2015 (lithium-ion batteries), and EU Regulation 2019/1020, fully complying with global new energy standards. After being used by a battery recycling company partnered with Shanxi Xinhuasheng Carbon, it passed environmental compliance verification.

X. Cost Analysis

Taking an annual production capacity of 1 million supercapacitors as an example, compare the cost differences between the activated carbon process and the traditional process:

project	High-specific surface area GAC + hydrophobic GAC process	Traditional Activated Carbon + Molecular Sieve Process
Initial Investment (Ten Thousand Yuan)	200-300	150-250
Cost per individual electrode (yuan)	15	10
Annual Operating Costs (Ten Thousand Yuan)	150（100+50）	200（150+50）
Total Life Cycle Cost (RMB per unit)	30-40	35-45
Annual Return Loss (Ten Thousand Yuan)	0	200
Net Income (Ten Thousand Yuan per Year)	18 (Cost Savings – Operating Costs)	-130 (Return losses – Operating costs)

XI. Why Choose Us?

Performance endorsement: We have served key new energy clients including Ningbo CRRC New Energy (China's first enterprise certified under GB/T 34870), Germany's BASF (with EU battery recycling certification), and U.S.-based Maxwell Technologies (a leader in supercapacitors). Our activated carbon, renowned for its "high specific capacity and long cycle life," has received unanimous acclaim. For instance, a supercapacitor manufacturer collaborating with Shanxi Xinhua Sheng Carbon achieved an increase in energy density from 4.5 Wh/kg to 15.8 Wh/kg after adopting our ultra-high specific surface area GAC, securing annual orders of 500,000 units from new energy vehicle manufacturers.

Technical capabilities: To meet the demands of new energy applications, we have developed three advanced GAC materials—ultra-high specific surface area GAC (with 76% micropores and a specific surface area of 2800 m²/g), hydrophobic GAC loaded with molecular sieves (with water adsorption capacity of 200–300 mg/g), and amino-modified GAC (achieving electrolyte recovery>99%)—effectively addressing the limitations of traditional processes such as low specific capacity and short cycle life.

Global Services: We operate production bases in Shanxi, Ningxia, and Fujian (with an annual capacity of 45,000 tons), offering a "customized production + localized delivery" solution. For international clients, we provide end-to-end services covering activated carbon selection, electrode process design, and new energy compliance certification, ensuring prompt response within 72 hours.