Commodity Production Costs Report

Carbon Fiber Production from Pitch

Carbon Fiber Operating Costs & Plant Construction Costs

1.5 kta United States-based plant | 107 Pages | Issue B | Q3 2024
Starting at $1,199 USD | See Report Editions Prices

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.

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.

Key reference(s): ?

Carbon Fiber Production Cost Report Process Schematic

The process under analysis comprises three major sections: (1) Pitch treatment and spinning; (2) Stabilization, carbonization and graphitization; and (3) Surface treatment and sizing.

Pitch treatment and spinning. The first step in the production of pitch-based carbon fiber consists in a pitch treatment, in which the petroleum pitch is converted into a liquid crystalline phase called mesophase pitch, with adequate spinnability. The treatment involves heating the pitch at 350-450°C using a mixture of oxygen and nitrogen for sparging. The mesophase pitch is cooled down and solidified, and then melt spun into pitch fibers. The mesophase pitch spinning is performed by termed melt extrusion.

Stabilization, carbonization and graphitization. The thermoplastic pitch fiber previously obtained is oxidized into infusible thermosetting fibers, by means of gas-phase oxidation, at 250 - 400°C. This stabilization aims to prevent softening and resulting deformation of the pitch fibers upon heating downstream. After stabilization, the pitch fibers are carbonized in a multi-zone furnace, under an inert atmosphere, in successive heating zones with temperatures increasing ranging from 700 to 2,000°C. The carbonization’s goal is to remove elements other than carbon from the fibers, and grows graphite crystals (graphitization). The carbonized fibers are then heated to higher temperatures (2,500 - 3,000°C), in order to increase carbon fiber’s tensile modulus of elasticity.

Surface treatment and sizing. The carbon fibers are submitted to anodic oxidation (electrolytic bath), so as to roughen filaments surface and introduce functional groups into the fiber surface (improving interfacial fiber/matrix bonding). The carbon fiber is then coated with a solution of resin, 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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Features
  • Production Process Information
  • Process Consumptions
  • Labor Requirements
  • Plant Capital Cost Summary
  • Operating Cost Summary
  • Production Costs Datasheet
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 80 Pages | 22 Tables | 9 Images

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Table of Contents


Features
  • Production Process Information
  • Process Consumptions
  • Labor Requirements
  • Plant Capital Cost Summary
  • Operating Cost Summary
  • Production Costs Datasheet
  • Plant Capital Cost Details
  • Operating Cost Details
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 90 Pages | 28 Tables | 13 Images

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Table of Contents


Features
  • 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
  • Costs in Different Countries Add-on
  • See All Features

  • 107 Pages | 34 Tables | 22 Images
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  • Updated with Q3 2024 Data
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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

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