Resource-Efficient Materials Fraunhofer IAP to Produce "Green" Carbon Fibers

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A new pilot plant in Germany will enable the production of bio-based carbon fibers in the future. To this end, the processes are now being transferred to an industrial scale and the processes are being optimized. The plant is part of the Carbon Lab Factory Lausitz.

Carbon fibers are high-performance materials that combine lightness with high strength and rigidity. They are particularly popular in lightweight construction—after all, it is an important lever for the development of high-performance and resource-efficient materials for key future industries. The lighter cars, airplanes, wind turbines or bicycles are, the more energy-efficiently they can be moved. But they are also becoming increasingly important for the generation, conversion and storage of energy, for example for batteries, fuel cells and other components of modern energy systems.

Conventional carbon fibers are mainly made from fossil raw materials. In order to expand the raw material base with sustainable alternatives, the focus is shifting to bio-based carbon fibers. They conserve resources, have a better CO₂ balance and make the value chain more resilient. In addition, their properties can be specifically adapted to different applications. The industry is already showing strong demand for such alternatives.

Transferring Processes to An Industrial Scale

The production of bio-based carbon fibers is a specialty of the Fraunhofer IAP: In a first step, raw materials—e.g. cellulose or lignin from wood—are dissolved and spun into precursor fibers. These are then converted into carbon fibres through carbonization.

In order to transfer these processes to an industrial scale, a pilot plant is to be built in Guben as part of the Carbon Lab Factory Lausitz. The 58 million dollars project is being financed by the Brandenburg Ministry of Science, Research and Culture via Wirtschaftsregion Lausitz GmbH (WRL) and the federal government. The city of Guben is investing around 22 million dollars in the construction of the building in the Guben Industrial Park. The Fraunhofer IAP will use the remaining funding for the plant technology, material resources and initial equipment. The facilities are scheduled to go into operation from the end of 2029.

Focus on the Process Behaviour During Carbonization

Dr. André Lehmann, head of the Polymer Processing research division and the Fiber Technologies department at the Fraunhofer IAP, explains: "With the Carbon Lab Factory Lausitz in Guben, we are creating the conditions for a research and pilot infrastructure with which a wide variety of innovative precursor fibers can be produced up to the tonne scale."

Dr Jens Erdmann, head of the Polymer Engineering department at the Fraunhofer IAP, adds: "We are also setting up a laboratory carbonization plant that converts the novel precursor fibres into carbon fibres on a kilogram scale. This will allow us to efficiently assess the process behavior and potential, optimize the processes and gain valuable insights for a larger scale. We are also able to provide the industry with sample quantities for testing."

In close cooperation with partners in Lusatia, the Fraunhofer IAP is further developing the precursor and carbon fibers for various lightweight construction and energy applications and will thus specifically strengthen the transfer to industrial use.

Carbon Lab Factory Lausitz: Cross-Border Cooperation

Complementary to the Fraunhofer IAP project, a pilot plant for the production of carbon fibers on a ton scale is being set up in Lusatia, Saxony. The plant, operated by Chemnitz University of Technology (Germany), can process both conventional fibers and precursor fibers provided by the Fraunhofer IAP.

In cooperation with the Institute for Lightweight Construction and Value Creation Management at the Brandenburg University of Technology Cottbus-Senftenberg (Germany), carbon fiber-reinforced composite materials are also being tailored for a wide range of lightweight construction applications. Together with regional companies, the partners are testing demonstrators and prototypes. In this way, research results are transferred more quickly into industrial applications and the region is strengthened as a center for high-performance materials.

The Carbon Lab Factory Lusatia is embedded in the research infrastructure in Lusatia. "By combining the expertise of the participating institutions, the Carbon Lab Factory Lausitz is creating a globally unique, complete value chain in the region and beyond. This extends from renewable raw materials to components for lightweight construction applications," says Professor Böker, Director of the Fraunhofer IAP, who initiated the Carbon Lab Factory Lausitz together with Professor Kroll from Chemnitz University of Technology (Germany).

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