There is provided a process and system for producing carbon fiber products. The process can involve deasphalting a heavy hydrocarbon feedstock, which can contain native asphaltenes, to produce a solid asphaltene particulate material, which can be further treated to produce the carbon fiber products. In some implementations, the solid asphaltene particulate material can be extruded in the presence of a polymer. In some implementations, the solid asphaltene particulate material can be chemically treated with a chemical agent including a Lewis acid, an oxidizing agent and/or a reducing agent before extrusion. In some implementations, the process can further produce activated carbon fibers.

There is provided a process and system for producing carbon fiber products. The process can involve deasphalting a heavy hydrocarbon feedstock, which can contain native asphaltenes, to produce a solid asphaltene particulate material, which can be further treated to produce the carbon fiber products. In some implementations, the solid asphaltene particulate material can be extruded in the presence of a polymer. In some implementations, the solid asphaltene particulate material can be chemically treated with a chemical agent including a Lewis acid, an oxidizing agent and/or a reducing agent before extrusion. In some implementations, the process can further produce activated carbon fibers.

Provided are a method for manufacturing a high yield and high performance mesophase pitch and a high yield and high performance mesophase pitch manufactured therefrom by hydrogenating, mesophase formation, thin film evaporation, solvent-extracting, filtering and then drying to obtain only mesogen components in flow-domained mesophase pitch and then mixing the mesogen components with an isotropic pitch as a solvent component. Further, the high yield mesophase pitch of the present disclosure exhibits high spinnability while maintaining whole anisotropy and exhibits a much higher production yield than existing mesophase pitches.

The present disclosure relates to a process for preparing carbon fibers. The process involves blending a carbon nano-material with a carbon material to obtain a homogenous blend, heating the homogenous blend to obtain mesophase pitch having particles with reduced mesophase sphere size followed by spinning the mesophase pitch to obtain the pitch fibers. The pitch fibers are then carbonized to obtain the carbon fibers. The carbon fibers prepared by the process of the present disclosure have improved tensile properties as compared to the conventional pitch based carbon fibers.

The present disclosure relates to a process for preparing carbon fibers. The process involves blending a carbon nano-material with a carbon material to obtain a homogenous blend, heating the homogenous blend to obtain mesophase pitch having particles with reduced mesophase sphere size followed by spinning the mesophase pitch to obtain the pitch fibers. The pitch fibers are then carbonized to obtain the carbon fibers. The carbon fibers prepared by the process of the present disclosure have improved tensile properties as compared to the conventional pitch based carbon fibers.

The present technology provides fibers containing high levels of asphaltene but low levels of sulfur and total metals, starting from highly asphaltenic feeds with significant levels of sulfur and total metals. Thus, the present technology provides fibers comprising at least 30 wt % asphaltenes, less than 1 wt % sulfur and less than 0.1 wt % of total metals based on the weight of the fiber. Further, methods of making such asphaltenic fibers are provided, as well as methods of preparing carbon fibers therefrom.

Systems and methods of production for consistently sized and shaped optically anisotropic mesophase pitch from vacuum residue, one method including supplying processed vacuum residue to an extruder; heating the processed vacuum residue throughout a horizontal profile of the extruder from an inlet to an outlet of the extruder; venting hydrocarbon off-gases from the extruder along the horizontal profile of the extruder from the inlet to the outlet of the extruder; and physically shaping the consistently sized and shaped mesophase pitch at the outlet of the extruder for production of carbon fibers.

Systems and methods of production for consistently sized and shaped optically anisotropic mesophase pitch from vacuum residue, one method including supplying processed vacuum residue to an extruder; heating the processed vacuum residue throughout a horizontal profile of the extruder from an inlet to an outlet of the extruder; venting hydrocarbon off-gases from the extruder along the horizontal profile of the extruder from the inlet to the outlet of the extruder; and physically shaping the consistently sized and shaped mesophase pitch at the outlet of the extruder for production of carbon fibers.

A method for producing a carbon fiber, the method comprising: (i) subjecting a continuous carbon fiber precursor having a polymeric matrix in which strength-enhancing particles are incorporated to a stabilization process during which the carbon fiber precursor is heated to within a temperature range ranging from the glass transition temperature to no less than 20° C. below the glass transition temperature of the polymeric matrix, wherein the maximum temperature employed in the stabilization process is below 400° C., for a processing time within said temperature range of at least 1 hour in the presence of oxygen and in the presence of a magnetic field of at least 1 Tesla, while said carbon fiber precursor is held under an applied axial tension; and (ii) subjecting the stabilized carbon fiber precursor, following step (i), to a carbonization process. The stabilized carbon fiber precursor, resulting carbon fiber, and articles made thereof are also described.

A method of making a carbon fiber comprising esterification of a lignin precursor with an acid, acid anhydride, or acyl halide, thereby forming a reduced T.sub.g lignin. Mixing the reduced T.sub.g lignin with a carbon residue selected from the group of coal based raw material, petroleum based raw material and combinations thereof, thereby forming a fiber precursor mixture; and spinning the fiber precursor mixture into a fiber. A method of making a carbon fiber comprising esterification of a lignin with an acid derivative, thereby forming a reduced T.sub.g lignin. Mixing the reduced T.sub.g lignin with a pitch, thereby forming a fiber precursor mixture; and spinning the fiber precursor mixture into a fiber. A method of making a carbon fiber comprising lowering the T.sub.g of a lignin material, thereby forming a reduced T.sub.g lignin. Mixing the reduced T.sub.g lignin with a carbon residue, thereby forming a fiber precursor mixture and spinning the fiber precursor mixture into a fiber.