Eco-Friendly Carbon Fibre: Manchester's Groundbreaking Lignin Conversion Technology

Innovative Process Converts Lignin to Carbon Fibre, Reducing Costs and Environmental Impact

Carbon fibre, crucial for industries like aerospace and automotive, is traditionally produced using expensive, petroleum-based materials, raising both costs and environmental concerns. Lignin, a by-product of cellulose production, presents a sustainable alternative. Typically discarded or used for energy, lignin has potential for high-value applications, including carbon fibre production.

In collaboration with Imperial College London, industry partner Lixea developed a patented process to convert lignin into carbon fibre at a small lab scale. The process uses ionic liquid technology to dissolve lignin and polyvinyl alcohol (PVA) as a spinning aid. This approach, producing high-lignin-content fibres (75-90%), significantly reduces costs by replacing petroleum-based materials with renewable, low-cost, and non-toxic alternatives, cutting production costs by three to five times.

To validate the technology at scale, researchers at The University of Manchester, led by Professor Jonny Blaker, developed a pilot-scale demonstration at the Fibre Technology Platform at the Henry Royce Institute. They utilized its wet spinning line, sourcing lignin from Lixea’s pilot plant, which extracts lignin from wood waste using the same ionic liquid, ensuring alignment with the company's existing processes. The team tested three types of lignins two from spruce sawdust and one from bagasse, a by-product of sugar production. The bagasse-derived lignin was found to be the most effective, enabling continuous fibre spinning at the pilot scale for the first time.

In this trial researchers found that controlling drying was essential to prevent fibre shrinkage, lignin solutions became more viscous over time, requiring adjustments to maintain quality, and spinneret design impacted fibre uniformity, indicating the need for further refinement. Moreover, the team successfully produced continuous fibres up to 5 metres long during the project. The next steps involve refining the fibre drying, collection, and carbonisation processes, which will be crucial for scaling up the technology in the UK. Manchester's success in scaling up this novel technology marked a significant milestone toward commercially viable, sustainable carbon fibre production. Professor Jonny Blaker, Professor of Biomaterials, expressed excitement about showcasing the scale-up potential of the pioneering process to create a low-cost, renewable alternative to conventional manufacturing.

He highlighted that, with the equipment and expertise available at the pilot facility, the team successfully produced continuous fibres using lignin from Lixea, addressing key challenges in formulation and fibre drying, while ensuring compatibility with Lixea's wood fractionation technology. He noted that this trial represented a significant step toward making cost-effective, renewable carbon fibre a reality. Looking ahead, it was emphasized that with continued advancements and industry collaboration, lignin-based carbon fibre could soon become a commercially scalable, high-performance, and environmentally friendly alternative to petroleum-derived materials. Manchester’s role in technology scale-up further reinforced its position as a leader in materials innovation and sustainable manufacturing.

Editor's Note:

The work being done to turn lignin into carbon fibre is a groundbreaking step towards sustainable manufacturing. This collaboration between Imperial College London, Lixea, and The University of Manchester marks a major shift in how we approach materials production. By using lignin, a by-product, as a resource, this project not only helps the environment but also offers a cheaper alternative to petroleum-based materials. Professor Jonny Blaker and his team’s success in scaling up the technology shows the great potential of lignin-based carbon fibre. The use of renewable, low-cost, and non-toxic materials could change industries, leading to more eco-friendly practices. Advancements like this are crucial in the fight against climate change. Using sustainable materials in sectors like aerospace and automotive is key to reducing our environmental impact. This project proves that innovation and teamwork can drive meaningful change. Manchester’s role in this project strengthens its reputation as a leader in materials science and sustainable manufacturing. The future of carbon fibre looks bright, and with continued progress, lignin-based carbon fibre could become a commercially viable, high-performance alternative. 

Skoobuzz believes this project is a great example of how science can help create a more sustainable and better future.