Professional Documents
Culture Documents
Alternative Approaches
and Recycling Methods
MAE298: Sustainable Manufacturing
Matthew Gabel
Curtis Yau
What is Carbon Fiber?
● Carbon fiber: the thin strand of crystallized carbon atoms whose structure is parallel to
the length in which the fiber is formed.
○ Thousands of strands can be weaved into yarn, which can then be woven into
fabric.
● Carbon Fiber Reinforced Polymers (CFRP): Common composite form of carbon fiber that
we are familiar with; bonded with thermosetting polymers
● Benefits:
○ High Tensile Strength
○ Low Weight to Strength Ratio
○ Thermally Resistant
○ Low Chemical Reactivity
○ Shaped Easily
How’s It Made?
● Types of Precursors
○ PAN → Product of the polymerization of acrylonitrile
(highly flammable and toxic in low doses)
○ Pitch → Produced through distillation of carbon-
based materials
● Spinning: Precursor material turns into fiber form
● Stabilizing: Mildly heated in an oxygen-rich environment so
that the carbon absorbs the oxygen to rearrange atomic
bonding pattern
● Carbonizing: Heated at extremely high temperatures
without oxygen to dispel all non-carbon atoms
● Treating the Surface: Oxidized to create better bonding
surface for epoxies, etc.
● Sizing: Fiber is coated, then twisted to form yarns of various
sizes.
Carbonization Furnaces
How Carbonization Changes the Fibers
Polyacrylonitrile (PAN) Method
● Acrylonitrile is comes from propene, a byproduct of
petroleum refinement
● Reaction occurs in a fluidized bed reactor
2CH3-CH=CH2 + 2NH3 + 3O2 → 2CH2=CH-C≡N + 6H2O
● Free radical polymerization
● Polymerization usually occurs with Sulfuric Acid
Polyacrylonitrile (PAN) vs Pitch
Nine Drops
Since 1930
End of Life Procedures
Steels 110-210
● There is <4% loss in tensile strength for recycled carbon fibers from pyrolysis; Young’s
Modulus stays the same, according to ELG Carbon Fibre Ltd.
○ Keep in mind this is using their proprietary processes.
● Researchers’ work shows varying results when keeping processes constant and using
different manufacturers’ CFRPS.
○ Generally, there is a slight strength decrease when pyrolysis is implemented.
○ There is the same strength decrease through chemical methods.
Conclusion
● Boeing estimates that recycled carbon fiber costs ~70% less than virgin carbon fiber
($8/lb-$12/lb vs. $15/lb-$30/lb), while using 5% of the energy used to make it.
● Orchid-based Pitch Carbon Fiber is comparable to PAN-based Carbon Fiber material
properties
○ The Orchid-based Pitch Carbon Fiber produces less ecological footprint than
PAN, although none of the carbon fiber breaks down naturally.
● Recycled carbon fiber has a length much shorter than virgin carbon fiber, which can be
spun into lengths however long the manufacturers want.
References
[1] “What is Carbon Fiber?” Internet: http://www.innovativecomposite.com/what-is-carbon-fiber/, 2015 [Dec. 10, 2017].
[2] “Thermoset vs. Thermoplastics.” Internet: http://www.modorplastics.com/plastics-learning-center/thermoset-vs-thermoplastics/, 2017 [Dec. 10, 2017].
[3] “How Products are Made: Carbon Fiber.” Internet: http://www.madehow.com/Volume-4/Carbon-Fiber.html, 2017 [Dec. 10, 2017].
[4] McConnel, Vicki. “The making of carbon fiber.” Internet: https://www.compositesworld.com/articles/the-making-of-carbon-fiber, Dec. 19, 2008 [Dec.
10, 2017].
[5] Maxineasa, Sebastian. (2015 July). “Environmental impact of carbon fibre-reinforced polymer flexural strengthening solutions of reinforced concrete
beams.” The International Journal of Lice Cycle Assessment. [Electronic]. Vol. 20. (10), 1343-1358. Available:
https://link.springer.com/article/10.1007/s11367-015-0940-5 [Dec 10. 2017]
[6] “Carbon Fiber: Oven Emission Control Strategies.” Internet: https://www.anguil.com/case-studies/composites-fiberglass-carbon-fiber/carbon-fiber-
oven-emission-control-strategies/, 2017 [Dec. 10, 2017].
[7] Wood, Karen. “Carbon fiber reclamation: Going commercial.” Internet: https://www.compositesworld.com/articles/carbon-fiber-reclamation-going-
commercial, Feb. 4, 2010 [Dec. 10, 2017].
[8] Limburg, Marco and Peter Quicker. “Disposal of Carbon Fiber Reinforced Polymers: Problems During Recycling and Impacts on Waste Incineration”
[Electronic]. Available: http://www.vivis.de/phocadownload/Download/2016_wm/2016_WM_221-236_Quicker.pdf [Dec 10. 2017]
[9] WSU News Posts. “Researchers develop recycling for carbon fiber composites.” Internet: https://news.wsu.edu/2017/05/01/wsu-recycling-carbon-
fiber-composites/, May 1, 2017 [Dec. 10, 2017].
[10] ELG Carbon Fibre Ltd. “Recycled Carbon FIbre: A New Approach to Cost Effective Lightweighting” Internet:
https://www.igcv.fraunhofer.de/content/dam/igcv/de/docs/Travelling_Conference_Unterlagen/03_Recycled%20Carbon%20Fibre_Gehr_ELGCF.pdf, [Dec.
10, 2017].
[11] Pimenta ,Soraia. (2011 Feb.) “Recycling carbon fibre reinforced polymers for structural applications: Technology review and market outlook”
[Electronic]. Vol. 31 (2), 378-392. Available: http://www.sciencedirect.com/science/article/pii/S0956053X10004976#tblfn29, [Dec 10, 2017].