Knowledge graphs (KGs) generated by large language models (LLMs) are becoming increasingly valuable for Retrieval-Augmented Generation (RAG) applications that require knowledge-intensive reasoning. However, existing KG extraction methods predominantly rely on prompt-based approaches, which are inefficient for processing large-scale corpora. These approaches often suffer from information loss, particularly with long documents, due to the lack of specialized design for KG construction. Additionally, there is a gap in evaluation datasets and methodologies for ontology-free KG construction. To overcome these limitations, we propose SynthKG, a multi-step, document-level ontology-free KG synthesis workflow based on LLMs. By fine-tuning a smaller LLM on the synthesized document-KG pairs, we streamline the multi-step process into a single-step KG generation approach called Distill-SynthKG, substantially reducing the number of LLM inference calls. Furthermore, we re-purpose existing question-answering datasets to establish KG evaluation datasets and introduce new evaluation metrics. Using KGs produced by Distill-SynthKG, we also design a novel graph-based retrieval framework for RAG. Experimental results demonstrate that Distill-SynthKG not only surpasses all baseline models in KG quality -- including models up to eight times larger -- but also consistently excels in retrieval and question-answering tasks. Our proposed graph retrieval framework also outperforms all KG-retrieval methods across multiple benchmark datasets. We release the SynthKG dataset and Distill-SynthKG model publicly to support further research and development.