CF & CFRP Market

CF & CFRP products are used in telescope antennas, brake discs, airframe structures, and other satellite components. Due to high modulus and thermal conductivity in heat dissipation, carbon fibers are in high demand from satellite manufacturers in applications such as space radiators or electronic enclosures. Apart from this, CF & CFRP are highly demanded for prepregs used in satellite precision structures and heat sinks. Carbon fiber prepregs offer superior thermal conductivity to help channel heat from electrical components. Carbon fiber’s low coefficient of thermal expansion ensures that satellite parts maintain their integrity and dimensional stability despite the harsh thermal environment. This stability is vital for maintaining the precision of sensitive instruments and systems on board the satellite. In August 2024, ISRO launched Earth Observation Satellite (EOS-8) featuring integrated avionics, miniaturized antennas, and a flexible solar panel that uses a CFRP honeycomb rigid end panel to enhance the panel’s structural integrity and power generation, illustrating EOS-08’s focus on lightweight, robust, and efficient satellite design.

The high cost of carbon fiber is mostly associated with the cost of raw materials or precursors used in the production. The most commonly used precursor for carbon fiber manufacturing is the exceptionally costly precursor polyacrylonitrile (PAN), which necessitates a highly complex and detailed manufacturing process. Carbon fiber production requires specialized equipment and skilled personnel to ensure the material’s quality and consistency. Additionally, CFRP are essential in industries like aerospace, automotive, and renewable energy due to their strength, lightweight nature, and chemical resistance. However, their production is costly and highly energy-intensive up to 14 times more energy-demanding than steel.

Due to the cost benefits, researchers are harnessing carbon in coal to create products such as carbon fiber and graphene. The price of carbon fiber lowers significantly when coal is used as feedstock. For instance, coal costs approximately USD 12/ton. On the other hand, an equivalent amount of petroleum (7 or 8 barrels) costs approximately USD 60/barrel. This means using coal as a precursor would be 30 or 35 times less expensive. Thus, companies and governments are investing in producing coal-based carbon fiber to achieve cost benefits. Ramaco Carbon is presently exploring various possibilities for using repurposed coal to make and use carbon fiber in the automotive industry. Ramaco has established a carbon ecosystem to achieve this and collaborated with the Wyoming Western Research Institute under the DOE project called Coal to Cars. The project has received funding of USD 5 million and focuses on using coal-based carbon fiber to decrease vehicle manufacturing costs. In addition, the University of Kentucky Research Foundation is also focusing on developing and scaling efficient processing technology for ultra-low quinoline insoluble (QI) coal tar pitch and subsequent mesophase pitch to simplify continuous fiber processing technologies toward the efficient production of high-performance carbon fiber products and demonstrate composite parts derived from the coal-to-carbon-fiber (C2CF) paradigm.

The high cost of PAN and pitch carbon fibers is one of the major concerns associated with its growth. Carbon fiber still has low usage in large applications due to its high cost. Developing low-cost technologies is a major challenge for researchers and key manufacturers. The production process for carbon fiber is highly energy-intensive, involving several stages, such as polymerization, stabilization, carbonization, and surface treatment. The high energy demand adds significant cost to the final product, making it difficult to lower prices while maintaining performance standards. Carbon fibers are used in critical applications like aerospace, automobiles, and sports equipment, where material quality and consistency are paramount. Achieving a balance between lowering costs and maintaining the high strength-to-weight ratios, durability, and other performance characteristics of carbon fiber is difficult. Carbon fiber composites are only introduced in high-end and luxury cars in the automotive industry due to their high cost. With the increased availability of low-cost carbon fiber, its usage in the automotive industry is expected to surge.