Future strategies for decarbonisation of carbon fibre products: A roadmap to Net Zero 2050

Abstract

Carbon fibre (CF) has unique specific mechanical properties that make it critical in achieving net zero targets through continued lightweighting of transportation as well as enabling large scale wind power generation and adjacent hydrogen energy storage solutions. Despite this, CFs continue to have high embodied carbon resulting from energy intensive processes used during production. This investigation uses lifecycle assessment to assess the impact of future energy scenarios and alternative feedstock materials in CF production, to generate data critical for informing long term decarbonisation strategies.Achieving net zero electricity generation alone can lead to approximately 50% reduction in CF Global Warming Potential (GWP), emphasising the critical importance of decarbonising electricity. This study also emphasises the imperative for lower-carbon solutions in the thermal energy used across the CF production value chain. Adopting BioMethane as a thermal energy alternative has the potential to achieve a 20% reduction in current GWP, offering a significant short-term mitigation strategy. Among thermal energy solutions, eMethane demonstrates the greatest long-term potential for CF decarbonisation, with a projected 99% reduction in GWP by 2050 compared to natural gas. Producers may consider BioMethane as a temporary solution (2025–2040) before transitioning to eMethane as the long-term thermal energy source (2035–2040 onwards) as electricity impact decreases. Additionally, it is recommended that producers prioritise switching to bio-based acrylonitrile feedstock for CF production, which is expected to reduce GWP by 5 – 9 kg CO₂e. per kg of CF.