Scientists Discover Innovative Method to Initiate Carbon Fiber Production Process
*New Study's Revelation: Enhancing Carbon Fiber Production's Energy Efficiency and Lowering Costs*
In an exciting discovery, researchers at North Carolina State University have found a promising method to boost the energy efficiency of a crucial stage in the production of carbon fiber - a material frequently used as a lighter, more fuel-efficient alternative to steel in vehicles, airplanes, and other products. This breakthrough was detailed in the Journal of Applied Polymer Science.
The researchers added two biologically derived chemicals, glucaric acid and mucic acid, found in certain fruits, to a precursor material for carbon fiber. Their experiment showed that with these additives, the energy required to initiate the chemical conversion process of making carbon fiber significantly decreased.
"Carbon fiber is in high demand, particularly for low-cost applications in structural vehicle components," said Ericka Ford, assistant professor of textile engineering, chemistry, and science at NC State. "In this study, we discovered that by incorporating the two chemicals into the precursor material, we might be able to reduce the amount of energy needed to complete one step of the carbon fiber manufacturing process, contributing to a decrease in costs."
Before adding the chemicals to the lab, researchers utilized computer modeling to anticipate their interaction with the precursor material. Their curiosity in the chemicals was sparked after glucaric acid, one of them, was listed by the U.S. Department of Energy as a chemical of industrial significance.
"We were intrigued by understanding how these chemicals would interact with the precursor material," said study co-author Hannah Dedmon, an NC State graduate student. "Utilizing computer models and simulations, we were able to examine their interaction parameters before even starting laboratory work. In this way, we can slow things down and gain insights into atomic-level details, which we're blind to in the lab."
Next, the researchers experimentally tested creating the precursor material, a plastic substance called polyacrylonitrile (PAN), which is sometimes referred to as an "acrylic."
The manufacture of carbon fiber from PAN is a "spinning" process that involves creating extremely fine filaments, similar to making cotton candy or a spider spinning a web, researchers explained.
First, they develop a gel-like substance with a consistency akin to honey. Then, they force the "honey" through a minute needle to transform into a small filament, like a tiny hair. Finally, they heat the hairs to extremely high temperatures, which assists in converting the PAN filaments into a structure that forms the basis of the carbon fiber.
The addition of the chemicals decreased the energy needed to launch the chemical reaction that creates the carbon structure from PAN five-fold. The researchers say this could also lower the overall cost of this processing step by making the reaction faster.
"These are small molecules with functional groups that are highly efficient at initiating the reaction," said the study's lead author Debjyoti Banerjee, doctoral candidate at NC State.
The researchers plan to explore other additives and possibly use computer models to predict the most promising candidates for maximizing value.
"We're interested in investigating other natural products that we could incorporate into PAN fibers and impact their usefulness for converting into carbon fiber," Ford said.
The research, titled "Cyclization kinetics of gel-spun polyacrylonitrile aldaric-acid sugars using the isoconversional approach," was authored by Banerjee, Dedmon, Ford, Farzin Rahmani, and Melissa A. Pasquinelli. It was funded by the NC State Chancellor's Innovation Fund.
Originally published in NC State News
- This innovation in carbon fiber production, as detailed in the Journal of Applied Polymer Science, could potentially lower costs for widespread use in vehicle components due to a reduced energy requirement in one stage of manufacturing.
- In a bid to enhance energy efficiency, researchers added two biologically derived chemicals, glucaric acid and mucic acid, to a precursor material for carbon fiber.
- The addition of these two chemicals lowered the energy needed to initiate the chemical conversion process of making carbon fiber by five-fold.
- Ericka Ford, a graduate from textile engineering, chemistry, and science at NC State, believes this discovery could lead to reduced energy consumption in the manufacturing of carbon fibers for health-and-wellness products like fitness-and-exercise equipment.
- To better understand the interaction between these chemicals and the precursor material, the researchers utilized computer modeling before commencing laboratory work.
- In the field of environmental science, this research could lead to more sustainable methods of carbon fiber production, contributing to the ongoing pursuit of eco-friendly technology.
- Dieticians and nutritionists might also benefit from a lower cost carbon fiber, as it could be used in lightweight, durable containers for healthful food storage.
- By exploring other natural products and using computer models, the researchers aim to maximize the potential of carbon fiber production, allowing for further advancements in research and development across various industries.
