Carbon Fibers Carbowave—Produce Carbon Fibers Energy-Efficiently

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A new technology uses microwaves and plasma heating to produce carbon fibers energy-efficiently. This allows high-strength composite materials to be produced more cheaply and sustainably. The research consortium Carbowave aims to improve and commercialize this microwave- and plasma-induced carbonization.

The combination of high strength and low weight makes carbon fibers almost indispensable in the production of modern lightweight products. Major industries such as the automotive industry, aerospace, and renewable energy sectors are increasingly relying on the use of high-strength carbon fiber composites.

As advantageous as the material is, its production is equally complex and energy-intensive: The stabilization and carbonization of the fibers, often made from petroleum-based polyacrylonitrile (PAN), require a slow process in high-temperature ovens. Despite the significant energy consumption, only a low material yield is achievable due to the long residence time in the ovens.

Local Energy Input into the Fibers

A completely new process uses microwave and plasma heating to replace the established stabilization and carbonization process with an energy-saving technique. The energy input into the fibers is localized using this technique, thereby minimizing energy loss. The process will help to shorten production times for carbon fibers, enabling higher production volumes with lower energy consumption.

Under the name 'Carbowave,' a European research consortium has come together to optimize and commercialize the process. The specific research goals are:

• the development of an optimal coating for PAN fibers that improves microwave adsorption,
• the development of a plasma heating system for the oxidative stabilization of PAN fibers and
• the technical development of microwave and plasma technology for continuous processes.

Reduce Energy Consumption in the Stabilization Process

The German Institutes for Textile and Fiber Research (DITF) are responsible for implementing the technology into continuous production processes and for its integration into pilot lines on a technical scale. The stabilization of precursor fibers using plasma technology is a central task of the DITF within the joint project. This also involves the implementation of a combination of plasma and low-pressure technology, aimed at reducing energy consumption during the stabilization process.

Consider Recycling

In the spirit of the circular economy, the Carbowave project incorporates the recycling of carbon fibers: The new process technologies are also intended to enable microwave-assisted decomposition of carbon fiber-reinforced composites (CFRP).

With this, the Carbowave research consortium provides a holistic approach that encompasses both the production and recycling of modern lightweight materials.

Carbowave is funded by the European Union under grant agreement no. 101192581.

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