King Abdullah University of Science and Technology ( KAUST ) has achieved a breakthrough in carbon fiber production by using synergistic mixtures of heavy petroleum residues. By using asphaltenes and resins as raw materials, the research team has developed a more efficient spinning process with lower energy consumption and higher carbonization yield.
More accessible carbon fiber production
Currently, carbon fiber production relies on polyacrylonitrile ( PAN ), an expensive precursor that accounts for up to 50% of total manufacturing costs. Using petroleum waste as an alternative reduces raw material costs and increases process efficiency.
[post_relacionado]This led us to hypothesize that blending asphaltenes with resins could create a synergistic feedstock for carbon fiber production.
Edwin Guevara Romero, researcher in Mani Sarathy’s laboratory.
The resulting fibers possess mechanical characteristics similar to isotropic fibers used in industrial applications. Furthermore, they demonstrated adequate tensile strength for sectors such as automotive , wind energy , and even biomedical devices .
By producing carbon fibers , the process improves the handling of the remaining oil. For example, by extracting the heavier compounds, the remaining residual oils can be more easily processed into cleaner fuels or high-value molecules.
The laboratory is collaborating with Saudi Aramco to scale this technology to an industrial level. Reusing heavy oils transforms a low-value waste product into a high-demand raw material, with applications in sectors requiring mechanical performance, durability, and lightness.
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Source and photo: KAUST