How NanoXplore pioneered graphene as a sustainable high-performance material

NanoXplore Inc. (NanoXplore) stands as the world's largest producer of graphene, with a production capacity of 5000 tons per year, accounting for approximately 40% of the global capacity. The company is uniquely positioned to supply graphene at an industrial scale cost-effectively. NanoXplore offers multiple grades of graphene tailored for various end-markets, including composites, plastics, oil and gas, thin films, and insulation foams. This is supported by a decade of proprietary process intellectual property and application expertise. NanoXplore's graphene, with a purity of 99.8% for its premium grade, is among the purest commercially available. Rocco Marinaccio, President and CEO, outlines the company's journey from its founding in 2011 to its current scale. "NanoXplore began as a technology startup focused on R&D until 2018, when we scaled up production from 25 tons to 5000 tons. We hold certifications to legally produce and sell graphene in Canada, the US, UK, and EU," he states.

Graphene, a single-atom-thick layer of carbon, was discovered in 2004. NanoXplore utilizes a proprietary exfoliation process to separate graphite into six to ten graphene layers. Despite the initial challenge of commercializing this new material, NanoXplore has become the largest graphene producer and has acquired companies in downstream industries to showcase graphene's value.

"We began acquiring composites companies in 2018 to demonstrate graphene's real-world applications and to generate stable cash flow," Rocco continues. "From zero revenue, we have grown to approximately $117 million, primarily from graphene-enhanced composites and plastics. Our relationships with companies like PACCAR, Volvo Truck, Club Car, and General Electric have expanded, and we plan to launch an additional $35 million in business over the next year."

NanoXplore is also expanding into other market segments where graphene's value is increasingly recognized. In the oil and gas sector, NanoXplore signed a five-year agreement with Chevron Phillips Chemical to use its Tribograf™ additive in drilling fluids, marketed as Nanoslide™. This additive reduces friction in drill strings, leading to a 17% reduction in drill time.

In the thin plastic films market, NanoXplore partnered with Techmer PM to enhance film strength by up to 70% using graphene. This allows for a 20% reduction in material usage, offering a more sustainable solution. NanoXplore filed a provisional patent for this product, launched at the Flexible Films Innovation and Recycling Conference in Milwaukee.

NanoXplore is nearing commercialization in the insulating foams segment, focusing on increasing the R-value of foams and replacing TCPP, a flame retardant being banned in the UK and Europe. "Graphene has been tested against numerous alternatives and is proving to be one of the only effective substitutes," Rocco elaborates.

The company's latest innovation is a dry exfoliation process, known as D-series graphene, which eliminates the need for chemicals and water. This process allows for compact production modules that can be installed at customer facilities, supporting decentralized growth. "By enhancing our technology and production capabilities, we have built the capacity to serve every market segment we target," Rocco concludes.

Graphene remains a strategic core for NanoXplore, which recognized its potential early on and continues to capitalize on its expanding commercial applications.