Systems and processes for producing low cost bulk random carbon fibers using asphaltene as a feedstock

Abstract

Systems and processes for producing short carbon fibers from an asphaltene-rich feedstock are disclosed. The asphaltene-rich feedstock are melted, filtered, and/or degassed before spinning into fibers. The molten feed may be spun using melt blowing or centrifugal spinning, to form random mats of discontinuous green fibers. These random mats of discontinuous fibers are suitable for transporting and processing using low-cost, standard bulk solids handling methods. In the methods discussed herein, the green fibers are first exposed within a reactor to a gas containing nitrogen dioxide (NO2) which infuses the fibers, thereby adding nitrogen oxide functional groups to the green fibers. The infused fibers are heated during which the infused fibers undergo oxidation leading to stabilization at low temperatures, allowing low softening point asphaltene-rich feeds to be successfully stabilized. The stabilized fibers are further heated in a substantially oxygen-free environment to carbonize the fibers to produce a random mat, discontinuous carbon fiber product. The produced random fiber material is suitable for blending into polymers or other matrices to produce random short carbon fiber reinforced products.

Dependencies are inferred from the claim text.