Carbon Fibers: From PAN to Asphaltene Precursors; A State-of-Art Review

Abstract

Due to their outstanding material properties, carbon fibers are widely used in various industrial applications as functional or structural materials. This paper reviews the material properties and use of carbon fiber in various applications and industries and compares it with other existing fillers and reinforcing fibers. The review also examines the processing of carbon fibers and the main challenges in their fabrication. At present, two main precursors are primarily utilized to produce carbon fibers, i.e., polyacrylonitrile (PAN) and petroleum pitch. Each of these precursors makes carbon fibers with different properties. However, due to the costly and energy-intensive processes of carbon fiber production based on the existing precursors, there is an increasingly growing need to introduce cheaper precursors to compete with other fibers on the market. A special focus will be given to the most recent development of manufacturing more sustainable and cost-effective carbon fibers derived from petroleum asphaltenes. This review paper demonstrates that low-cost asphaltene-based carbon fibers can be a substitute for costly PAN/pitch-based carbon fibers at least for functional applications. The value proposition, performance/cost advantages, potential market, and market size as well as processing challenges and methods for overcoming these will be discussed.