Carbon Fibers Based on Cellulose–Lignin Hybrid Filaments: Role of Dehydration Catalyst, Temperature, and Tension during Continuous Stabilization and Carbonization

Lignocellulose has served as precursor material for carbon fibers (CFs) before fossil-based polymers were discovered as superior feedstock. To date, CFs made from polyacrylonitrile have dominated the market. In search of low-cost carbon fibers for applications with medium strength requirements, cellulose and lignin, either as individual macromolecule or in combination, have re-gained interest as renewable raw material. In this study, cellulose with 30 wt% lignin was dry-jet wet-spun into a precursor filament for bio-based carbon fibers. The stabilization and carbonization conditions were first tested offline, using stationary ovens. Diammonium sulfate (DAS) and diammonium hydrogen phosphate were tested as catalysts to enhance the stabilization process. Stabilization is critical as the filaments’ strength properties drop in this phase before they rise again at higher temperatures. DAS was identified as a better option and used for subsequent trials on a continuous carbonization line. Carbon fibers with ca. 700 MPa tensile strength and 60–70 GPa tensile modulus were obtained at 1500 °C. Upon further carbonization at 1950 °C, moduli of >100 GPa were achieved.