New plasma and microwave technology could cut energy use in carbon fibre manufacturing by 70%.
A research team at the University of Limerick (UL) has developed a groundbreaking method for producing carbon fibre while significantly reducing its energy consumption. The CARBOWAVE project, led by UL’s Professor Maurice N Collins and Dr Anne Beaucamp McLoughlin, is replacing traditional heating processes with an innovative plasma and microwave-based approach, cutting energy use by up to 70% without compromising material performance.
A greener, more affordable alternative
Carbon fibre is a high-cost, lightweight material used across industries like aerospace, wind energy, construction, and transportation. Its production is notoriously energy-intensive, heavily reliant on electricity and natural gas. CARBOWAVE’s alternative heating technology makes the process greener and more affordable, offering a potential transformation for the sector.
The project’s first results, published in the Advanced Composites and Hybrid Materials Journal, highlight its potential to tackle environmental challenges while contributing to sustainable industrial growth. By improving the conversion of Polyacrylonitrile (PAN)—a crucial precursor in carbon fibre production—the CARBOWAVE team aims to revolutionise manufacturing efficiency. PAN requires a significant amount of energy to convert into carbon fibre, making it a strategic material for Europe’s energy security.
Microwave heating: A surprising bbreakthrough
The team employs susceptor-induced microwave heating using self-assembled nanostructures, a technology initially developed by researchers at UL and the University of Valencia. This technique enables faster, more efficient heating of PAN, streamlining the carbon fibre production process. UL researchers found that carbon fibre can even be produced using a domestic microwave, achieving mechanical performance on par with conventionally heated fibres.
Industry experts weigh In
Professor Collins, principal investigator on the project and Professor of Materials Science at UL’s School of Engineering, emphasised the broader impact of CARBOWAVE: “Europe’s reliance on energy-intensive processes has long been a barrier to achieving sustainability. CARBOWAVE addresses this challenge and is an exciting project which offers the potential to produce more sustainable and cheaper carbon fibre.
The long-term implications are enormous, as it could allow the deployment of carbon fibre in all sorts of applications where high strength and stiffness are needed, from construction and transportation to hydrogen storage and wind energy.”
Dr Anne Beaucamp McLoughlin, Assistant Professor in Civil Engineering at UL and co-principal investigator explained the project’s goal: “This project aims to revolutionise the carbon fibre industry by significantly reducing the energy consumption and cost of the carbon conversion process without losing mechanical properties.
This project will allow for carbon fibre production to be more energy efficient, faster, and cheaper, significantly reducing its environmental footprint.”
Why it matters
Carbon fibre reinforced polymers (CFRPs), derived from carbon fibre, are key to wind energy, construction, and transportation sectors. Their lightweight properties enhance wind turbine efficiency, support decarbonisation in construction, and improve fuel efficiency in transport, particularly in electric vehicles. However, the high energy demands of current carbon fibre production remain a major challenge.
By reducing energy use by more than 70% while maintaining performance, CARBOWAVE’s innovations provide a viable solution. Europe, which holds a 37% share of the global advanced carbon materials market, stands to benefit directly from this initiative.
Looking ahead
Professor Collins noted: “This project promises to unlock the broader industrial use of carbon fibre by drastically reducing its production costs and environmental footprint.
CARBOWAVE represents a step toward decarbonising Europe’s energy-intensive industries. By integrating plasma and microwave heating technologies, the project not only addresses immediate challenges like energy consumption and emissions but also paves the way for sustainable industrial growth.”
The CARBOWAVE consortium brings together leading research institutions and industry partners across Europe, including the Deutsche Institute für Textil- und Faserforschung in Germany, the University of Valencia in Spain, Fraunhofer IFAM in Germany, Microwave Technologies Consulting SAS in France, Muegge GmbH in Germany, Centro Ricerche Fiat in Italy, Juno Composite Ltd in Ireland, and Eirecomposites Ltd in Ireland.
A European-backed initiative
Funded by the European Commission, CARBOWAVE is dedicated to implementing alternative heating sources for energy-intensive industries. By leveraging plasma and microwave technologies, the project sets a precedent for sustainable industrial transformation, reducing both costs and carbon footprints in the carbon fibre sector.