Carbon Fiber Production from PAN Fiber
Carbon Fiber Production Costs Report | Issue A | Q2 2024
Report Details |
2.50 kta United States-based plant | Q2 2024 | 107 pages | Delivered in PDF |
This report presents a cost analysis of a 2.50 kta (kilo metric ton per annum) United States-based plant. You can add a customized cost analysis, assuming another location (country), when ordering a premium edition of this report.
Report Abstract
This report provides a techno-economic analysis of a typical Carbon Fiber production process starting from polyacrylonitrile (PAN) fiber in the United States. In this process, PAN fiber is first stabilized. The stabilized PAN passes then through carbonization, surface treatment and sizing, before being winded.
The report provides a comprehensive study of Carbon Fiber production and related Carbon Fiber production cost, covering three key aspects: a complete description of the Carbon Fiber production process examined; an in-depth analysis of the related Carbon Fiber plant capital cost (Capex); and an evaluation of the respective Carbon Fiber plant operating costs (Opex).
The Carbon Fiber production process description includes a block flow diagram (BFD), an overview of the industrial site installations, detailing both the process unit and the necessary infrastructure, process consumption figures and comprehensive process flow diagrams (PFD). The Carbon Fiber plant capital cost analysis breaks down the Capex by plant cost (i.e., ISBL, OSBL and Contingency); owner's cost; working capital; and costs incurred during industrial plant commissioning and start-up. The Carbon Fiber plant operating costs analysis covers operating expenses, including variable costs like raw materials and utilities, and fixed costs such as maintenance, labor, and depreciation.
Process Schematic
The process under analysis comprises three major sections: (1) Stabilization; (2) Carbonization and graphitization; and (3) Surface treatment and sizing.
Stabilization. The PAN precursor fiber is oxidized into infusible thermosetting fibers through gas-phase oxidation at 230-250 °C. This stabilization (thermosetting) aims to prevent softening and resulting deformation of the pitch fibers upon heating downstream.
Carbonization and graphitization. After stabilization, the PAN fibers are carbonized in a multi-zone furnace, under an inert atmosphere, in successive heating zones with temperatures increasing from about 700 to about 1,700 °C. The carbonization’s goal is to remove elements other than carbon from the fibers and to grow graphite crystals (graphitization). The carbonized fibers are then heated to higher temperatures (2,500-3,000 °C) to promote the growth of the ordered structure, increase crystalline orientation in the fiber direction, and reduce the interlayer spacing (increasing carbon fiber’s tensile modulus of elasticity).
Surface treatment and sizing. The Carbon Fiber is submitted to anodic oxidation (electrolytic bath) to roughen the filament surface and introduce functional groups into the fiber surface (improving interfacial fiber/matrix bonding). The Carbon Fiber is then coated with a resin solution to protect it in downstream operations and keep filaments adhered together in individual tows. Finally, the Carbon Fiber is wound onto bobbins and stored.
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Production Process Information
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Plant Capital Cost Summary
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Production Costs Datasheet
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Production Process Information
Process Consumptions
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Operating Cost Summary
Production Costs Datasheet
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Operating Cost Details
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Production Process Information
Process Consumptions
Labor Requirements
Plant Capital Cost Summary
Operating Cost Summary
Production Costs Datasheet
Plant Capital Cost Details
Operating Cost Details
Plant Cost Breakdowns
Plant Capacity Assessment
Process Flow Diagrams
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Content Highlights
Plant Capital Cost Summary
Summary outlining the capital cost required for building the Carbon Fiber production plant examined
Plant Capital Cost Details
Detailing of fixed capital (ISBL, OSBL & Owner’s Cost), working capital and additional capital requirements
Plant Cost Breakdowns
Breakdown of Carbon Fiber process unit (ISBL) costs and infrastructure (OSBL) costs; plant cost breakdown per discipline
Operating Costs Summary
Summary presenting the operating variable costs and the total operating cost of the Carbon Fiber production plant studied
Operating Cost Details
Detailing of utilities costs, operating fixed costs and depreciation
Plant Capacity Assessment
Comparative analysis of capital investment and operating costs for different Carbon Fiber plant capacities
Production Process Information
Block Flow Diagram, descriptions of process unit (ISBL) and site infrastructure (OSBL)
Process Consumptions
Raw materials and utilities consumption figures, by-products credits, labor requirements
Process Diagrams
Process flow diagrams (PFD), equipment list and industrial site configuration
Other Carbon Fiber Production Cost Reports
Carbon Fiber Production from Pitch
This report presents a feasibility study of a process for Carbon Fiber production from petroleum pitch in the United States. The process starts with a preparation step that converts the pitch into mesophase pitch. The mesophase pitch is then stabilized and passes through carbonization, graphitization, surface treatment and sizing, before being wound.
Details: 1.50 kta United States-based plant | Q2 2024 | 107 pages | Issue B From $1,199 USD
The cost analyses presented in this report target a 1.50 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.
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Other Related Production Cost Reports
Polyacrylonitrile Production
This report presents a techno-economic analysis of Polyacrylonitrile (PAN) Precursor production in the United States via aqueous dispersion polymerization of acrylonitrile with methyl acrylate comonomer followed by transformation steps to become a fiber.
Details: 9 kta United States-based plant | Q2 2024 | 107 pages | Issue A From $799 USD
The cost analyses presented in this report target a 9 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.
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