Bitumen-Derived Carbon Fibers: A Low-Cost and Sustainable Alternative for Advanced Material Production

Abstract This work explores the feasibility of producing low-cost carbon fibers (CFs) from bitumen-derived precursor materials. The objective is to develop CFs with competitive mechanical properties through optimized feedstock modification, fiber spinning, and thermal treatment. This research supports Alberta’s economy by creating alternative high-value products from its abundant oil sands. It could offer a cost-effective alternative to polyacrylonitrile (PAN)-based CFs, addressing material availability and cost challenges in industries such as automotive, aerospace, and energy. Raw and modified bitumen fractions were investigated as precursor materials for CF production. The approach included: (i) feedstock modification to improve fiber properties; (ii) advancements in spinning techniques to control fiber morphology and diameter; and (iii) development of optimized thermal treatment protocols for stabilization and carbonization. These steps were implemented iteratively to enhance mechanical performance while maintaining cost efficiency. Characterization of the resulting CFs involved mechanical strength and microstructural analysis to assess their feasibility as a competitive alternative to PAN-based CFs. This study demonstrates that CFs with tensile strength exceeding 1500 MPa, modulus over 250 GPa, strain around 1%, and diameters below 20 µm can be produced from bitumen-derived precursors with minimal chemical modification and no additives. Results suggest that bitumen-derived CFs could provide a cost-effective alternative to traditional CFs, broadening their application potential. Upscaling production capability from kilogram-per-week to kilogram-per-day quantities is currently underway, advancing towards industrial feasibility. Further refinement of formulation and processing techniques is ongoing to enhance consistency and scalability. This research contributes to the state of knowledge by demonstrating the viability of bitumen-based CFs with high mechanical performance. Unlike most prior research that relies on extensive precursor modification or additives, the presented approach achieves competitive properties from lower value starting materials, with minimal processing. These findings offer a promising pathway for the petroleum industry to valorize these asphaltene-rich, bitumen type feedstocks, creating new high-value non-combustion products.