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A research team from the University of Limerick in Ireland has made significant strides in carbon fibre production by introducing a novel method that promises to greatly decrease its energy usage.
The University of Limerick (UL) is at the forefront of this initiative, called the CARBOWAVE project, which focuses on developing a cost-effective and lightweight material that is widely employed in industries ranging from aerospace to construction and renewable energy.
This innovative approach combines plasma and microwave heating techniques to manufacture carbon fibre, replacing traditional energy-hungry processes. Remarkably, this advancement could reduce energy consumption during production by up to 70%, all while preserving the high-performance characteristics of the material.
The initiative, overseen by Professor Maurice N. Collins and Dr. Anne Beaucamp McLoughlin of UL, aims to revolutionize the carbon fibre sector, which has long been criticized for its high energy demands. By incorporating state-of-the-art heating technologies, CARBOWAVE seeks to promote sustainability and economic feasibility in the industry.
The initial findings of this research have been documented in the journal Advanced Composites and Hybrid Materials, and they represent a crucial step towards mitigating environmental challenges such as excessive energy consumption and greenhouse gas emissions, while also fostering sustainable industrial growth.
One of the key components in carbon fibre production is Polyacrylonitrile (PAN), which traditionally requires a large amount of energy for conversion. This project directly addresses the energy-intensive nature of PAN conversion, making it a pivotal aspect of Europe’s ambitions for energy security.
The CARBOWAVE team is leveraging a technique known as susceptor-induced microwave heating, which utilizes self-assembled nanostructures developed through collaboration with researchers from both the University of Limerick and the University of Valencia. This method facilitates quicker heating, resulting in a more efficient production process.
Intriguingly, the research team found that carbon fibre can also be produced using standard domestic microwaves, yielding mechanical performance similar to that derived from traditional heating methods.
Professor Maurice Collins, the project’s principal investigator and professor in the School of Engineering at UL, stated: “The dependence on energy-intensive processes in Europe has been a significant obstacle to achieving a sustainable future. CARBOWAVE confronts this issue head-on and presents an exciting opportunity to create more environmentally friendly and lower-cost carbon fibre.”
“The potential ramifications are substantial, as this could enable the use of carbon fibre in various applications requiring high strength and rigidity, from construction and transportation to hydrogen storage and renewable energy,” he continued.
Co-principal investigator Dr. Anne Beaucamp McLoughlin, who is an Assistant Professor in Civil Engineering at UL, noted that the project is designed to transform the carbon fibre sector by minimizing energy use and costs while retaining the material’s essential mechanical properties.
“Our work aims to enhance the efficiency and speed of carbon fibre production, significantly reducing its environmental impact,” she added.
Carbon fibre reinforced polymers (CFRPs), which are synthesized from carbon fibre, are increasingly vital in several industries, including renewable energy, construction, and transportation. The lightweight nature of CFRPs significantly boosts wind turbine performance, aids in the decarbonization efforts of the construction industry, and enhances the fuel efficiency of vehicles, particularly electric ones.
Nevertheless, current carbon fibre production methods remain heavily reliant on electricity and natural gas, making them highly energy-intensive.
The CARBOWAVE initiative targets a reduction in energy consumption of over 70%, all while ensuring that the material’s performance remains intact. This ambitious project is poised to have a direct positive impact on Europe’s advanced carbon materials market, which currently accounts for 37% of the global market share.
Professor Collins remarked: “The promise of this project lies in its potential to facilitate a broader application of carbon fibre by substantially lowering production costs and its environmental footprint.”
“CARBOWAVE represents a significant stride towards decarbonizing energy-intensive sectors in Europe. By integrating innovative plasma and microwave technologies, this initiative not only aims to resolve immediate concerns related to energy use and emissions but also lays the groundwork for sustainable industrial growth in the future.”
The project brings together top research institutions and industry players from across Europe. The CARBOWAVE consortium includes partnerships with the Deutsche Institute für Textil- und Faserforschung in Germany, the University of Valencia in Spain, Fraunhofer IFAM in Germany, and several other entities from France, Italy, and Ireland.
CARBOWAVE is funded by the European Commission, aiming to promote the development and implementation of alternative energy sources for energy-intensive industries by harnessing advanced plasma and microwave technologies.
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