Bio-Based Carbon Fiber Innovation: Process Optimization for Continuous Pitch Production

Abstract

The global demand for sustainable and high-performance materials has driven significant interest in bio-based carbon fiber as a viable alternative to petroleum-derived counterparts. This study explores the optimization of continuous pitch production processes for the development of carbon fiber using renewable bio-precursors, with a focus on improving material performance, scalability, and environmental compatibility. By employing a process engineering framework, the research investigates critical variables such as precursor composition, carbonization temperature, and residence time in a continuous production setting. Experimental trials were conducted using lignin-derived and cellulose-based pitch precursors, with results assessed through mechanical testing, thermal analysis, and morphological characterization. Findings demonstrate that precise control of process parameters can significantly enhance the tensile strength, surface morphology, and yield of bio-based carbon fibers, achieving competitive performance metrics relative to conventional carbon fibers. Furthermore, the study assesses the environmental and economic implications of bio-based fiber production through a life cycle lens, highlighting reduced carbon footprints and alignment with circular bio economy goals. The outcomes offer practical insights for industrial scaling and inform policy recommendations aimed at promoting green manufacturing innovation. This research contributes to the emerging field of sustainable composite materials and underscores the transformative potential of bio-based alternatives in advanced engineering applications.