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Lower Cost, Higher Performance Carbon Fiber: C. David (Dave) Warren
Lower Cost, Higher Performance Carbon Fiber: C. David (Dave) Warren
Performance
Carbon Fiber
14 February 2011
C. David (Dave) Warren
Field Technical Manager
Transportation Materials Research
How can the cost of carbon fiber suitable for higher performance
applications (H2 Storage) be developed?
Can we build off of work previously done for more modest structural
applications?
Outline:
Technology development & potential industries
The cost of making Carbon Fiber.
The paths taken for structural materials.
2
Potential paths for higher performance fiber cost reduction.
Managed by UT-Battelle
for the U.S. Department of Energy Presentation_name
Fiscal Year: 2010 2011 2012 2013 2014 2015 2016 2017
Lignin Based Precursors
Moderate Property Vinyl Acetate Textile PAN
Low Cost Polyolefin Precursors
Structural
Alternative Polyolefin Constituent Precursor Development and Processing
Precursors
Graphite Electrodes for Arc Furnaces Lignin
4 Managed by UT-Battelle
for the U.S. Department of Energy Presentation_name
Potential Markets and Needs
Materials
250-500 KSI, 25 MSI Fiber 500 - 750 KSI, 35 - 40 MSI Fiber
Current Potential
Industry Benefit Applications Drivers Obstacles
Market Market
Cost: Need $5-7/lb;
Mass Reduction:
Fiber Format;
10% Mass
Throughout Body Tensile Modulus; Compatibility with > 1B
Automotive Savings translates < 1M lbs/yr
and Chassis Tensile Strength automotive resins, lbs/year
to 6-7% Fuel
Processing
Reduction
Technologies
Cost and Fiber
Blades and
Availability;
Enables Longer Turbine Tensile Modulus;
Compression
Blade Designs Components that Tensile Strength to 1-10 M 100M - 1B
Wind Energy Strength; Fiber
and More Efficient must be mounted reduce blade lbs/yr lbs/yr
Format &
Blade Designs on top of the deflection
Manufacturing
towers
Methods
Low Mass, High Cost and Fiber
Deep Water Pipes, Drill Shafts,
Strength, High Availability; 10 - 100M
Oil & Gas Production Off-Shore < 1M lbs/yr
Stiffness, Corrosion Manufacturing lbs/yr
Enabler Structures
Resistant Methods
Low Mass, Zero Cost; Cable Designs;
Zero Coeficient of
CTE transmission High Volume
Electrical Storage Reliability & Thermal Expansion; 10-100M
cables; Flywheels Manufacturing < 1M lbs/yr
and Transmission Energy Storage Low Mass; High lbs/yr
for Energy Processes; Resin
Strength
Storage Compatibility
Hydrogen Storage,
Affordable Storage High Strength; Light Cost; Consistent
Pressure Vessels Natural Gas < 1M lbs/yr 1-10B lbs/yr
Vessels Weight Mechanical Properties
Storage
Potential Markets and Needs (Continued)
Materials
250 - 500 KSI, 25 MSI Fiber 500 - 750 KSI, 35 - 40 MSI Fiber
Current Potential
Industry Benefit Applications Drivers Obstacles
Market Market
Retrofit and Repair
Bridge Design, of Aging Bridges and
Tensile Strength & Cost; Fiber Availability;
Bridge Retrofit, Columns;
Stiffness; Non- Design Methods; Design
Seismic Retrofit, Pretensioning 1-10M 1-100B
Infrastructure Corrosive; Standards; Product
Rapid Build, Cables; Pre- lbs/yr lbs/yr
Lightweight; Can be Form; Non-Epoxy Resin
Hardening against Manufactured
"Pre-Manufactured" Compatibility
Terrorist Threats Sections; Non-
Corrosive Rebar
Lightweight Ground
Ship Structures; Low Mass; High Cost; Fiber Availability;
Non-Aerospace and Sea Systems; 1-10M 10-100M
Support Equipment; Strength; High Fire Resistance; Design
Defense Improved Mobility lbs/yr lbs/yr
Tanks; Helicopters Stiffness into Armor
and Deployability
Consumer Low Mass; Electical 1-10M 10-100M
Electronics EMI Shielding Cost; Availability
Electronics Conductivity lbs/yr lbs/yr
Fairings; seat Cost of lower
Secondary structures; luggage High Modulus; Low performance grades; 1-10M 10-100M
Aerospace
Structures racks; galley Mass Non-Epoxy Resin lbs/yr lbs/yr
equipment Compatibility
Enabler for Structural Design Tensile Strength & Design Concepts;
Non-Traditional
Geothermal and Members; Thermal Stiffness; Non- Manufacturing Methods; 1-10M 10M-1B
Energy
Ocean Thermal Management, Corrosive; Fiber Cost; Fiber lbs/yr lbs/yr
Applications
Energy Conversion Energy Storage Lightweight Availability
Electircal Li-Ion Batteries; Electrical and Design Concepts; Fiber 1-5M 10-50M
Key Storage Media
Energy Storage Super-capacitors Chemical Properties Cost and Availability lbs/yr lbs/yr
6 Managed by UT-Battelle
for the U.S. Department of Energy Presentation_name 11-70M 3-114B
Total
lbs/yr lbs/yr
So What is the difference between making aerospace
and industrial grade carbon fiber?
Materials
Attribute Industrial Grade Aerospace Grade Cost Impact
Tow Size 12‐80K Filaments 1‐12K Filaments Less material throughput
Precursor Content < 92% AN, MA or VA > 92% AN, MA Little on raw material; slower
oxidation
Precursor purity & Can tolerate more Controls UTS and Slower spinning speed
uniformity impurity compression
strength
Oxidation Quicker due to Slower due to Time is money
lower AN higher AN
Carbonization Lower Temp Sometimes Higher Small impact
Temp
Surface treatment Same but utility Same None but Load Transfer affects
affected amount of fiber needed
Packaging Spooled Small Spools More Handling
Certification None Significant Expensive; Prevents incremental
Improvements.
Essentially the same process with slightly different starting materials. Not
7
captured is the fact the CF manufacturers are specialty material makers,
Managed by UT-Battelle
for the U.S. Department of Energy
not Presentation_name
high volume.
So What is the difference between making aerospace
and industrial grade carbon fiber?
Materials
An higher performance fiber during production has:
1. Less material throughput (smaller tow size).
2. Requires more care in spinning (to get round fibers).
3. Spends longer in oxidation (affects lbs/hr production).
4. And requires higher temperature carbonization (energy $).
Textile Virgin
Textile Chemically
Treated
Fully
Oxidized
8 Managed by UT-Battelle
for the U.S. Department of Energy Presentation_name
Strength/Modulus vs. Temp
Textile Based Precursors
Materials
Strength (KSI)
32 Msi
Temperature *Fortafil F3 (C)
450
500 29 400
350
450 28 300
400 250
27
Elastic Modulus (Msi)
Tensile Strength (Ksi)
200
350 *Panex 33 150
300 26 100
50
250 25 0
200 24
Stretched Unstretched
150
23 Tension
100 Modulus (MSI)
50 22
0 21 35
30
1 2 3 4 5 6 7
25
Carbonization Temperature
20
Based on broom straw test method measured in our labs (Not from Co. brochure) 15
10
Cost US$
Significant Cost Reduction can
be achieved by increased Scale-
up of Plant and Line Size
per lb of CF
Mfg Cost $
Baseline Scale-Up
But
Not All the Needed Cost
11 Reduction
Managed by UT-Battelle Annual Production Capacity
for the U.S. Department of Energy Presentation_name
* Baseline Data From Kline & Company
Carbon Fiber Costs (2. Precursors)
Materials
Alternative Precursors and
More Affordable Precursors are Needed Conventional Processing
3 Current Precursor Options
1. Textile Grade PAN (MA or VA formulations)
2. Lignin Based Precursor (Hardwood or Softwood)
3. Polyolefins (not shown on chart)
500
Commercialization Goal
400 Textile Properties:
Program Goal
300
Strength: 540 KSI
200
100
Modulus: 38 MSI
0
PE: H H H H H
86% C Content;
65-75% Yield C C C C C
$0.50-$0.75/lb; Processed Precursor Fibers from a
12 Managed by UT-Battelle
MeltforSpun
the U.S. Department of Energy Presentation_name Hardwood/Softwood Lignin Blend.
H H H H H
Current Research (3. Conversion)
Materials
Alternative Processing Methods Under Development
Current Generation of Oxidative Alternative Processing
Stabilization Equipment
3 Processing Methods
1. Advanced Oxidative
Stabilization
2. MAP Carbonization
3. Surface Treatment
(Not on graph)
MAP
Carbonization/
Graphitization
13 Managed by UT-Battelle Unit
for the U.S. Department of Energy Presentation_name
Advanced Surface Treatment
Cost Reduction (4. Processing)
Materials
Resin
Strength: 1.72 GPA 400
(250 KSI)
300
Program Goal
200
Current Properties:
100
Strength: 3.72 GPA
(540 KSI) 0
Goal 8‐8 10‐29 1‐3 1‐6 1‐25 3‐13 3‐17 3‐27 9‐18 10‐9 3‐19 6‐25 7‐24 5‐18
0.1002, 7%
0.69, 23%
0.62, 21% 0.1265, 9%
0.77, 26%
0.52, 18% 0.04, 3%
16 Managed by UT-Battelle
for the U.S. Department of Energy Presentation_name
Melt-Spun PAN Project
Materials
BASF developed melt-spun PAN precursor in the 1980’s
– Carbon fibers were qualified for B2 bomber
– Demonstrated 400 – 600 ksi fiber strength and 30 – 40 Msi modulus; even
better properties were thought to be achievable
– PAN content was 95% - 98% (consistent with high strength)
18 Managed by UT-Battelle
for the U.S. Department of Energy Presentation_name
Potential Paths for Higher Performance CF cost reduction
Materials
4. Couple New Precursor with Advanced Processing
(Mid to Long -Term)
1. Cost reduction can be a function of both a lower cost precursor and less
expensive processing methods.
2. Would result in a critical path of activities.
CF Grade Example of Combining Savings
Key
1- Baseline Precursor
2- Plasma Textile PAN Soft Wood
US $/lb of Carbon Fiber
19 Managed by UT-Battelle
for the U.S. Department of Energy Presentation_name
Potential Paths for Higher Performance CF cost reduction
Materials
5. Increase Competition and Suppliers
Part of the multi-industry approach being pursued.
Global Carbon Fiber Production - Estimated Capacity 2010
Not included is a 40,000,000 lb/year Chinese plant to come on-line after 2010 and a large
Russian plant under Contruction.
Small Tow* Large Tow* Total
Production, Production, Production,
Company Headquarters Manufacturing Sites lbs/year lbs/year lbs/year
AKSA Turkey Turkey 4,000,000 4,000,000
Cytec US – SC US‐SC 5,000,000 5,000,000
Dalian Xingke China China 1,320,000 1,320,000
Grafil ‐ Mitsubishi US – CA US ‐ CA 4,400,000 4,400,000
Hexcel US – UT US ‐ UT, AL 16,000,000 16,000,000
Kemrock India INDIA 1,430,000 1,430,000
Mitsubishi ‐ Rayon Japan Japan, US‐CA 13,530,000 6,000,000 19,530,000
SGL Germany Germany, UK, US‐WY 14,300,000 14,300,000
Toho Japan Japan, US‐TN 29,620,000 29,620,000
Toray Japan Japan, US‐AL 39,440,000 660,000 40,100,000
Yingyou China China 484,000 484,000
20 Totalby UT-Battelle
Managed 115,224,000 40,260,000 155,484,000
for the U.S. Department of Energy Presentation_name
Source: McConnell, V. “The Making of Carbon Fiber”, CompositesWorld, 19 December 2008.
Comparison of Impact
Materials
Comparison of Energy CO2 Plant Operating Precursor Total Mfg Best
Technologies kBTU/lb Emitted Cost Cost $/lb Cost $/lb Cost $/lb Properties
/lb of CF $/lb CF CF CF CF Achieved
Conventional 389 49.2 8.72 2.71 4.02 7.85 Baseline
Precursors (CC)
Conventional 272 34.4 4.28 1.34 4.02 6.05 Baseline
Precursors (AC)
Textile PAN – MA 389 49.2 5.56 2.06 2.90 5.74 Should
(CC) exceed 450
KSI
Textile PAN‐MA 272 34.4 3.57 1.20 2.90 4.64 Should
(AC) exceed 450
KSI
Melt‐Spun PAN 18.04 3.36 1.62 8.34 400‐600 KSI
(CC)
Melt‐Spun PAN 138 19.4 1.62 Should match
(AC) Conventional
21
CC – Conventional Conversion
Managed by UT-Battelle
AC – Advanced Conversion
for the U.S. Department of Energy Presentation_name
LM002
Questions?
22 Managed by UT-Battelle
for the U.S. Department of Energy Presentation_name
The Carbon Fiber Team
Materials
23
Robert Norris
Managed by UT-Battelle
Ken Yarborough Ronny Lomax Fue Xiong
for the U.S. Department of Energy Presentation_name
The Carbon Fiber Team
Materials
The entire team
contributed to this
presentation!!!!
26 Managed by UT-Battelle
for the U.S. Department of Energy Presentation_name
Textile PAN – Strength & Modulus
Textile Based Precursors
Materials
Target Properties: Current Properties:
600
Strength: 1.72 GPA (250 KSI) Strength: 3.72 GPA (540 KSI)
500
Strength (Ksi)
400
Commercialization Goal
300
Program Goal
200
100
0
Goal 8‐8 10‐29 1‐3 1‐6 1‐25 3‐13 3‐17 3‐27 9‐18 10‐9 3‐19 6‐25 7‐24 5‐18
29 Managed by UT-Battelle
for the U.S. Department of Energy Presentation_name
Carbon Fiber Property Goal
Materials
1100
1000
900
PBO Zylon
800
PBO
Tensile Strength (Ksi)
700
600 PAN
Targets
M5
E‐Glass Boron Fiber
500
Kevlar
Low TM
400 Nicalon SiC
Cost ‐
Spectra 1000
300
Structural
MESOPHASE PITCH
200 Nylon
RAYON
Steel
Alumina
100 Aluminum
0 ISOTROPIC PITCH
0 20 40 60 80 100 120 140
Tensile Elastic Modulus (Msi)
Source: 1) Modified from J.G. Lavin, ‘High Performance Fibers’, Ed John Hearle, Chapter 5, Woodhead Publishing, 2001, 2) Peter Morgan, Carbon Fibers and Their Composites,
Taylor &Francis 2005, 3) A.R.Bunsell, Fibre reinforcements for composite materials, Elsevier, 1987
40 2008
Brent Crude Oil -2009
20