Black Swan Graphene Inc. (SWAN-X) is planning on building a graphene production facility in Quebec as part of its overall strategy to become a major supplier to the concrete and polymer sectors.

The company, which is majority owned by Quebec-based Mason Graphite Inc., intends to increase its annual graphene production capacity from its current level of 40 tonnes to approximately 10,000 tonnes within the next few years.

This massive expansion will be carried out by a modular and scalable approach to rising demand for graphene, which is gaining traction as a niche product with positive implications for sustainable development.

The Quebec plant is expected to become operational within the next three years and will see Black Swan leverage low cost renewable hydro power in Quebec as part of a major push to accelerate the deployment of graphene usage across North America.

As a prelude to ramping up its global graphene production capacity, Black Swan has recently rolled out of a series of new Graphene Enhanced Masterbatch (GEM) products.

One such GEM product being launched is a new thermoplastic polyurethane (TPU) masterbatch, a versatile polymer that combines the properties of rubber and plastic, which the company describes as a "revolutionary addition" to its GraphCore 01 product line.

"We have garnered commercial interest from several potential customers, showcasing our new GEM's applicability in various industries, including clothing, inflatables and sporting goods," Michael Edwards, chief operating officer of Black Swan, said in a July release.

Distribution partnership with shareholder Thomas Swan

An important driver of GEM sales for Black Swan is its minority shareholder, U.K.-based Thomas Swan & Co. Ltd.. an advanced materials manufacturer with a global supply network of over 80 countries, which entered into a partnership deal with its namesake spinoff. 

Announced in January, the deal will see Thomas Swan Ltd. distribute Black Swan's GEM products through its Polymer Performance Solutions division focused on rubber and polymer markets, a move Black Swan expects will "significantly broaden" its global market presence. 

The deal is expected to not only spur growth in worldwide demand for graphene but also allow Black Swan to foster greater adoption of the material by attracting industrial customers ready to take advantage of its unique properties.

The application of GEM to bio-based and recycled polymers enhances the sustainability of various products by improving tensile strength, impact resistance and barrier properties. These features enable manufacturers to reduce their carbon footprint by producing compostable consumer packaging materials.

Graphene reduces concrete carbon emissions 

One key application of graphene is to be found in a concrete industry responsible for eight per cent of global carbon emissions. Graphene can reduce the amount of cement required in concrete, thereby lowering carbon dioxide emissions. 

"Concrete is one of the two main markets that we're focusing on which will have a significant sustainable (impact)," Edwards told Sustainable Biz Canada. "By incorporating small percentages of graphene, as little as 0.01 per cent, for example, you can reduce the amount of cement required in concrete by 20 per cent because graphene allows you to manufacturer a stronger form of concrete.

"Graphene enhances the compressive strength of concrete, allowing for the use of less material while maintaining or improving structural integrity, and this in turn can lead to lighter and more efficient construction."

The addition of graphene to concrete increases compressive strength by up to 146 per cent, flexural strength by as much as 15.6 per cent, as well as enhancing split tensile strength. This results in a new form of resilient concrete that cracks less while resisting stress better. 

The first fruits of Black Swan's application of graphene to concrete came last May when the company signed a contract to supply graphene for use in strengthening 180 tonnes of concrete for the construction of an industrial park near Redruth, England.

"Polymers is also an area where graphene can play an important role," Edwards added. "You can increase lightweighting in the auto industry by reducing the amount of polymer used in the manufacture of different components in cars - fenders, body panels, et al. - that reduce overall vehicle weight and improve engine efficiency and EV (electric vehicle) range."

Graphene adoption still in infancy 

Edwards is cognizant of the challenge of stimulating adoption of graphene in industries which have only lately begun to embrace the material's properties and applications. 

Graphene, first discovered in 2004, is composed of a single layer of carbon atoms arranged in a flexible hexagonal lattice a million times thinner than a human hair, yet is 200 times stronger than steel.

"It's been only 14 years since the Nobel Prize was awarded for the discovery of graphene and North America is only now beginning to take the adoption of graphene far more seriously," Edwards said.

"The concrete industry understands very well the opportunity that graphene provides it as does the polymer industry. We're addressing both those markets as well as engaging in discussions with global industrial companies ranging from sportswear to packaging.

"So the story is finally getting out there and I think Black Swan is a key part of ensuring that graphene will continue to grow in importance."