Production Cost Report
ICC - Is Bespoken: 0
ICC - Main References: ?
ICC - Issue: A
ICC - Volume: 272
ICC - Report ID: 272-A
ICC - Report Location: United States
ICC - Is Popular: 0
ICC - Is Developed: 1
ICC - Title: Carbon Fiber Production from PAN Fiber
ICC - Show Overview: 1
ICC - Report Location ID: 1
ICC - Plant Capacity Unit ID: 14
ICC - Volume Reports List: 272-B
ICC - Related Reports List: 271-A
ICC - Report Location Code: USA
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ICC - Prices: {"versions":{"1":{"1":"1199","2":"1199","3":"1199"},"2":{"1":"1999","2":"1999","3":"1999"},"3":{"1":"3399","2":"3399","3":"3399"}},"currency":"USD"}
ICC - Plant Capacity Unit Name: kilo metric ton per annum
ICC - Plant Capacity Unit Short Name: kta
ICC - Process Overview Image: //cdn.intratec.us/images/icc/process-overview/272-A.jpg
ICC - Process Overview Text: <h6>Product</h6> <p><b>Carbon Fiber</b>. Carbon Fiber (a.k.a. Carbon Fiber Reinforced Plastic, CFRP) is a fiber containing at least 90% carbon by weight, obtained by pyrolysis of an appropriate precursor fiber. It is a fiber used as yarns, felt, or powder like short monofilaments with diameters smaller than 10 micrometers, consisting of at least 92 wt% carbon. They are mainly applied to reinforce polymers, in the same manner that glass fibers, but presenting superior stiffness, combined with high strength and low density.</p> <h6>Raw Materials</h6> <p><b>Chemicals</b>. </p> <b>Polyacrylonitrile</b>. Polyacrylonitrile (also known as PAN) is a polymer resin mainly composed of acrylonitrile. This important acrylic resin is used in the production of a wide range of products, from ultra-filtration membranes to high-quality carbon fibers. PAN resins can be produced by any free-radical method. On commercial scale, the most common methods are suspension (or aqueous dispersion) polymerization and solution polymerization; emulsion polymerization is used only for some specific compositions. The use of bulk polymerization is limited because of the autocatalytic nature this method. PAN fiber precursor is produced by dissolving the PAN polymer in dimethylformamide (DMF), forming a dope. The dope is pumped through a spinneret into a precipitating bath, for the coagulation of the solution thread line into a highly swollen gel yarn, which must still be treated and finished before being fed to Carbon Fiber plant.</p>
ICC - Process Schematic Image: //cdn.intratec.us/images/icc/process-schematics/272-A.jpg
ICC - Process Schematic Text: <p>The process under analysis comprises three major sections: (1) Stabilization; (2) Carbonization and graphitization; and (3) Surface treatment and sizing.</p><p>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. </p><p>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).</p><p>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.</p>
ICC - Short Description: 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.
ICC - Main Product: Carbon Fiber
ICC - Plant Capacity: 2.50
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Carbon Fiber Production from PAN Fiber

Carbon Fiber Production Costs Report | Issue A | Q2 2024

Production Cost Report

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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.

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Production Process Information

Process Consumptions

Labor Requirements

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Operating Cost Summary

Production Costs Datasheet

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Production Process Information

Process Consumptions

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Production Costs Datasheet

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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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