Iranian scientists develop low-temperature pathway for converting non-graphitisable polymers into graphene

Iranian researchers have unveiled an innovative low-temperature method for converting non-graphitisable polymers into graphene-based structures, a development that could reshape the future of energy storage, advanced carbon materials and next-generation technologies. This is reported by IRNA, a partner of TV BRICS.

The study demonstrates that a polymer typically resistant to graphitisation can be transformed into graphene and graphite-like structures at 1100°C, without the use of catalysts, additives or complex industrial equipment. This approach challenges long-held assumptions that such polymers require temperatures near 3000°C or specialised high-pressure systems to undergo graphitisation.

Researchers attribute this breakthrough to the hierarchical micro-porous architecture within the polymer microspheres. These pores – narrow, ink-bottle-shaped cavities – act as confined “nano-reactors”, trapping the aromatic fragments released during carbonisation. Instead of escaping, these fragments reorganise within the restricted space, enabling the fusion of benzene rings and initiating the gradual formation of graphene layers.

Spectroscopic and structural analyses reveal a step-by-step transformation: early ring fusion begins around 250°C, aromatic network expansion emerges near 450°C, graphene layers start forming around 900°C, and graphite-like stacking appears at 1100°C. Raman spectroscopy, electron diffraction and high-resolution microscopy all confirm the presence of ordered graphene sheets within the heat-treated samples.

The significance of this achievement lies in its simplicity and cost-effectiveness. Conventional routes for converting non-graphitisable polymers into carbon-based materials rely on metal catalysts or extreme processing environments. This new method requires only a controlled heating programme and relies on the natural confinement of molecular by-products within nanoscale pores – enabling graphitisation under ambient pressure and dramatically reducing production costs.

According to the researchers, the confined-space mechanism is the central driver of this transformation. The nanoscale pores limit molecular movement, guide chemical rearrangement and lower the energy threshold for graphene formation. This reveals a previously unrecognised pathway for converting resistant polymers into graphitic materials at far lower temperatures.

The findings open the door to scalable, low-cost production of graphene and advanced carbon materials, with promising implications for battery technologies, high-performance electrodes, capacitors, energy-storage systems and a range of carbon-based applications.

Photo: Jacob Wackerhausen / iStock