Upscaling the Production of Polyethylene-Based Precursor Fibres for Carbon Fibre Manufacturing: Challenges and Solutions

On the road to developing more sustainable and cost-efficient carbon fibres (CFs), replacing the conventional polyacrylonitrile (PAN) precursor with polyethylene (PE) is a promising alternative. Yet most PE-CF studies focus on fibre properties at laboratory or pilot scale and largely overlook scalability—especially in melt-spinning, where precursor filament counts have typically been limited to 32–100, far below industrial CF tows (1000–48,000). This study addresses that gap by (i) modifying a staple-fibre melt-spinning line (MSFP) to directly produce a 10,000-filament PE precursor and (ii) demonstrating inline filament merging on an industrial yarn (IDY) plant at Institut für Textiltechnik (ITA) as a pragmatic scale-up route. Direct 10 k spinning proved technically feasible but did not meet convertibility targets owing to inhomogeneous extrusion and quench: the MSFP precursor showed 18.1 ± 2.0 µm filament diameter, 21.9 ± 3.8 cN/tex tenacity and 130.8 ± 40.8% elongation (total solid draw ratio 2.02). In contrast, the IDY route delivered a fine and uniform precursor with a 9.43 ± 0.02 µm filament diameter, 38.42 ± 0.43 cN/tex tenacity, 15.91 ± 0.76% elongation, and 15.32 ± 1.16% shrinkage at 120 °C (total solid draw ratio 4.55). After discontinuous sulfonation, TGA indicated superior cross-linking of the IDY precursor (≈15% mass loss at 400–600 °C) versus MSFP (≈18%). Inline merging doubled filament count inline and small-scale plying enabled a 6 k tow. Transferring the IDY precursor into continuous sulfonation and carbonisation yielded PE-based CF with a filament diameter < 8.5 µm, tensile strength up to 2.0 GPa, tensile modulus up to 170 GPa, and elongation at break up to 1.75%, without surface defects. The results establish a clear scale-up roadmap: prioritise homogeneous fine-filament extrusion at low throughputs, co-develop segmented quench, and use a stepwise strategy (1–2 k filaments → inline merging → ≥6 k) to enable industrially relevant, cost-effective PE-based CF production.