energy-efficient conversion of methane-derived carbon into

Energy-Efficient Conversion of Methane-Derived Carbon into Valuable Carbon FibersChao Wang, Johns Hopkins UniversityTeam Members: Liangbing Hu, UMD; Satish Kumar, Georgia Tech; Ping Liu, UCSD

We aim to develop an energy-efficient, scalable approach to convert methane-derived carbon into valuable graphitized carbon fibers.

Total project cost: $1.5MLength 24 mo.

Project Vision

Award #: DE-AR0001191Annual Review Meeting(Jan 14, 2021)

The Concept

‣ Feedstock: amorphous or partially graphitized carbon black (LQC) derived from methane pyrolysis (thermal black)

‣ Approach/Innovation:– Gel or blow spinning of LQC fibers– Direct Joule heating for upgrading

LQC fibers to high-strength, graphitized carbon fibers

1Energy-Efficient Conversion of Methane-Derived Carbon into Valuable Carbon FibersJanuary 26, 2021

The Concept and the Project Objectives‣ Concept:

– Convert methane-derived carbon black into valuable carbon fibers– Feedstock: amorphous or partially graphitized carbon black (LQC) derived from

methane pyrolysis (thermal black)– Approach/Innovation:

• Gel or blow spinning of LQC fibers• Direct Joule heating for upgrading LQC fibers to high-strength, graphitized carbon

fibers (GCFs)

‣ Project objective:– 1st year: spin carbon black of <100 nm into fibers and upgrade them into GCFs– 2nd year: manufacture GCFs from 3 types of methane-derived carbon– Final deliverables: continuous production of GCFs with 1 GPa of tensile strength at

cost of <$3/kg and carbon footprint of <0.2 g-CO2/g-GFC

The Team‣ Chao Wang (PI, JHU): chemical conversion and

thermal upgrading, characterization ‣ Satish Kumar (co-PI, Georgia Tech): carbon fiber

(gel) spinning‣ Liangbing Hu (co-PI, UMD): direct Joule heating,

blow spinning‣ Ping Liu (co-PI, USCD): TEA/T2M, characterization


Chao Wang Satish Kuman Liangbing Hu Ping Liu

Blow Spinning of LQC Fibers

4Insert Presentation NameJanuary 26, 2021

M1.2 (Q3): Blow Spin 0.5 Mpa LQC fabrics from one methane-derived carbon black with 0.5 g/h throughput (continuous operation) and 40 wt.% polymer binder.

Results: Fibers with 40 wt% PAN and 60 wt% thermal black (>250 nm) up to 11 MPa tensile strength and continuous spinning at ~0.6 g/h throughput.

CB/polymer fibers produced by dry-jet spinning Extruded fiber from a 200 µm diameter spinneret

Continuous fibers on plastic spools (roll-to roll processing)

Gel Spinning of LQC Fibers Using Thermax Carbon Black (CB)M1.1 (Q2): Gel Spin 0.5 MPa LQC fibers from one commercial carbon black (<100 nm) with 0.5 g/h throughput (continuous operation) and 40 wt.% polymer binder (PAN). M3.1 (Q2): Upgrade LQC fibers to GCFs (>100 MPa) with 0.1 g/h throughput (batch operation).

Results: Fibers with 40 wt% polymer binder (PAN) and 60 wt% thermal black (>250 nm) up to 265 MPa tensile strength (~18 μm in diameter) and continuous single filament spinning at ~ 14 g/h throughput.

Welding of Carbon Black upon Upgrading


CB12-43: 60 wt.% CB + 40 wt.% PAN

before treatment

CB12-43: 60 wt.% CB + 40 wt.% PAN

10 µm5 µm 5 µm 200 nm

Cross session

500 nm

Surface

Cross-session

200 nm

5 µm

Fibril + CB

Welding of Carbon Black upon UpgradingSEM

10 nm

BF-STEM

CB

PAN derived carbon fibrilFFT

200 nm

CB

PAN derived fibrilCB

Challenges and Potential Technical Partnerships

Major Risks Prioritized Milestones for Mitigation1. Spinning methane-derived LQC into fibers. This has not been reported before. The granular structure of LQC places a grand challenge in fiber processing.

Addressed. Both gel and blow spinning methods are able to generate LQC fibers from thermal black precursors (>250 nm)

2. Direct Joule heating of LQC fibers for upgrading can be challenged by the relative low conductivity and lack of structure control.

Pretreatment will be employed to partially pyrolyze the carbon/polymer composite fiber first at low temperatures to increase the electrical conductivity; thermochemical upgrading will be studied for parameter optimization and benchmarking; electrothermal pyrolysis of methane will be coupled with direct Joule heating to strengthen crosslinking.

3. System integration will be challenged by the type of carbon source and overall cost

Carbon source will be down-selected via cooperation with the other methane pyrolysis project teams; TEA will guide the process design and provide cost control


T2M/TEA


• PAN precursor needs to be very cheap (<<$3/kg, 60% yield) or replaced by LQC (<$1/kg, 100% yield) in large ratio (>80%LQC)

• With electricity cost reduction to ¢3 /kWh (DOE goal by 2030), projected cost $3.82 /kgCF

2020 CF Production Sensitivity ($4.73/kgCF)

Electricity in 2020:¢6.45 /kWh

2030 CF Production Sensitivity ($3.82 /kgCF)

Electricity in 2030:¢3 /kWh

~$6 /kgCFusing high PAN ratio

energy-efficient conversion of methane-derived carbon into

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