Prospects and Challenges of Carbon Fiber Production from Heavy Petroleum Fractions

Engineering, automotive, and aviation sectors increasingly seek carbon fiber due to its exceptional strength and lightweight properties. Although polyacrylonitrile (PAN)-based carbon fiber is the most widely available type, its excessively high cost prevents its widespread use. Research efforts are increasing globally to develop inexpensive carbon fibers using coal tar pitch and low-value petroleum feedstocks, such as asphaltenes, as alternatives to the present PAN-based (polyacrylonitrile) carbon fibers. The low-value heavy petroleum fractions have significant potential based on factors such as availability, chemical structures, economic diversification, and environmental considerations. However, the manufacturing of carbon fiber from the inexpensive petroleum fraction presents numerous obstacles that require attention. This review comprehensively evaluates the potential and obstacles associated with utilizing heavy petroleum fractions as an alternative feedstock for carbon fiber (CF) production. It provides an overview of carbon fibers and their production from a variety of sources. It then explores advancements in different techniques for producing carbon fiber precursors from heavy petroleum fractions. It also discusses the prospects, challenges, and research gaps in this field. Finally, it offers insights into future directions and suggestions for overcoming obstacles and advancing in the field.