Preliminary

Table of contents

I. Introduction ...................................................................................................

1

II. About CFs.................................................................................................

2

1. Characteristics of CFs ...........................................................................

2

2. PAN-based CFs .....................................................................................

4

3. Pitch-based CFs ....................................................................................

6

III. Uses and demand for CFs ...........................................................................

8

1. Main uses of CFs ...................................................................................

8

2. Expected demand for CFs ...................................................................

14

IV. Global warming countermeasure efforts .................................................

15

1. Global warming countermeasure efforts to date ................................

15(1) CF life cycle inventory (LCI) .......................................................

15(2) Technological development of CF recycling................................

17

2. Long-term vision for global warming countermeasures .....................

20(1) Contributions to reducing CO2 emissions at the product use stage20(2) Efforts to reduce CO2 emissions at the CF manufacturing stage

26(3) Recycling efforts ...........................................................................

28

V. Technological innovation efforts (introduction of national projects,etc.).............................................................................................................

33

1. Innovative CF basic technology development ....................................

33

2. Sustainable hypercomposite technology .............................................

35

3. National Composite Center (NCC)....................................................

36

4. Strategic Innovation Promotion Program (SIP)“Structural Materials for Innovation” ...............................................

38

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VI. Requests to the government for low-carbonization of CFs (reduce CO2
emissions) ......................................................................................................

40

VII. Conclusion..............................................................................................

41

Reference materials...................................................................................

42

1. CF LCI data........................................................................................

42

2. Major domestic and international CFRP recycling commercializationcompanies and research institutions......................................................

43

3. Framework for carbon neutrality by the Carbon Fiber Manufacturers
Association.............................................................................................

47

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I. Introduction
To date, the Japan Carbon Fiber Manufacturers Association Committee of theJapan Chemical Fibers Association (hereafter referred to as “The Japan Carbon Fiber
Manufacturers Association”) has promoted the quantification and appeal of the CO2
emission reduction effect of using carbon fibers (CFs) via life-cycle assessment (LCA)
models for objects, such as aircraft, automobiles, and wind turbines. In terms ofrecycling, a pilot plant was constructed in Omuta City, Fukuoka Prefecture, in the late
2000s, as a subsidized project by the Ministry of Economy, Trade and Industry ofJapan, and a feasibility study on CF recycling was conducted. Based on the activitiesof the Carbon Fiber Recycling Technology Development Association from 2012 to2014, this feasibility study has continued with the eventual goal of commercialization.
In this way, the Carbon Fiber Recycling Technology Development Body has madesignificant accomplishments in terms of CFs as materials that contribute to the global
environment.
In October 2020, the Japanese government set an ambitious goal of achievingcarbon neutrality by 2050. Maximum efforts from the public and private sectors are
essential for achieving this goal, and this should be linked to economic growth in Japan,
creating a continuous cycle between the economy and environment.
The Carbon Fiber Manufacturers Association would like to reconsider how torealize a carbon-neutral and sustainable society and create jobs and to grow while
contributing to the achievement of goals common to all humankind. To achieve thesegoals, here, we summarize the long-term outlook for the field of global environmental
conservation, where CFs can make the greatest contribution, and we describe ourvision.
The companies in the Carbon Fiber Manufacturers Association will continue toundertake these challenges; however, multiple challenges are difficult to handle
through the efforts of our industry alone. We would like to ask for the continued
support of the government and the understanding and cooperation of all CF users.
The Japan Carbon Fiber Manufacturers Association Committee,
Japan Chemical Fibers Association
October, 20221

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II. About CFs
CFs are defined as follows in the ISO and JIS standards. Based on the type of precursor 1, CFs
are classified as polyacrylonitrile (PAN)-type, pitch-type, etc.
ISO 2076 “A fiber containing at least 90% by mass of carbon obtained by thermal
carbonization of organic precursors.”
JIS L204-2 “A fiber composed of carbon at a mass ratio of 90% or more, obtained byheating and carbonizing an organic fiber precursor.”

1. Characteristics of CFs
CFs have a weight that is one-fourth that of steel, a strength per unit weight (specificstrength) that is 10 times that of steel, and a resistance to deformation per unit weight(specific elastic modulus) that is seven times that of steel, making them a light, strong,and difficult-to-deform material. Other properties include resistance to thermal
expansion, good dimensional stability, excellent durability (such as rust resistance,
fatigue, and creep resistance), excellent X-ray transparency, chemical resistance, heat
resistance, and electrical conductivity. Therefore, CFs are fibers with various functions.

Table/Figure 1. Specific strength and specific elastic modulus of CFs

Precursor: Here, it refers to the prior form of CF.

1

2

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Table/Figure 2 shows a comparison of the main physical properties (representativevalues) of PAN-based CFs, anisotropic pitch-based CFs (graphite thread), and isotropic
pitch-based CFs (graphite).

Table/Figure 2. Comparison between major textures/structures and physical propertiesof various CFs

3

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2. PAN-based CFs（1） Manufacturing method
The manufacturing of PAN-based CFs is roughly divided into two processes: 1) a
spinning process, where acrylic fibers are obtained as a raw yarn by polymerizing themonomer acrylonitrile (AN), and 2) a calcination process, where acrylic fibers are madeflameproof and carbonized to obtain CFs.
① Spinning process
AN and a solvent are mixed, a catalyst is added and polymerized, and a spinning
dope is prepared.
The spinning dope is extruded into a poor solvent in the form of fibers and solidified.
Subsequently, it is washed with water (washing), stretched, oiled, dried, and wound up
as an acrylic fiber.

Table/Figure 3. Manufacturing method of PAN-based CFs (raw thread)② Calcination process
First, acrylic fibers are heat-treated in the air at 200–300 ℃ to stabilize them,
thereby converting them into flame-resistant yarns with a high heat resistance (flame
proofing process). Next, elements other than carbon are burnt off at an ultra-hightemperature of 1000–3000 °C in an inert gas to obtain fibers that have a graphite
structure (carbonization/graphitization process). The fired CFs are surface-treated toincrease the adhesion to the matrix resin, and a sizing agent is added to improve thehandling of the fibers, after which they are wound on a bobbin and made into the final
product, namely CFs.

4

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Figure 4. Manufacturing method for PAN-based CFs (calcination)（2） Fiber structure
In a single CF, sheet-like graphite crystals are arranged parallel to the fiber direction.
Observation of the surface and sides via scanning tunneling microscopy (STM) andtransmission electron microscopy (TEM) shows graphite crystals lined up, as presented
in the photograph in Fig. 5; however, in reality, a single CF has a random onion-likestructure 2.
The crystallinity is approximately 0.5–0.8, and approximately half of the CFs used forgeneral purposes are amorphous. The crystal size varies considerably depending on the
calcination temperature; however, in the case of general products, it is approximately 1.7
nm for general-purpose grades and approximately 7 nm for high-elastic-modulus grades.

Table/Figure 5. CF structure

Onion structure: multi-layer structure similar to that of an onion

2

5

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3. Pitch-based CFs
For pitch-based CFs, naphtha-derived ethylene bottom oil (petroleum-based) or coaltar (coal-based) are used as the initial material, low-boiling-point components are
removed, and the material is made heavier by applying heat treatment to obtain a pitch
suitable for spinning. After the pitch is extruded through a narrow nozzle to form a fiber,
it undergoes infusibilization, carbonization, and graphitization processes and results in
the CF. The fiber diameter is determined based on the magnification by which the molten
pitch is drawn shortly after it is extruded through the nozzle and before it is solidified.
Pitch-based CFs are categorized into two types depending on the initial material:
1) “isotropic pitch,” which is optically disordered and does not exhibit polarization, and2) “anisotropic pitch (mesophase pitch),” where constituent molecules are arranged in aliquid-crystal state and exhibit optical anisotropy.

Table/Figure 6. Classification of pitch-based CFs

6

PreriminaryLarge differences in the texture/structure and physical properties exist between
anisotropic pitch-based and isotropic pitch-based CFs; anisotropic pitch-based CFs
resemble natural graphite or highly oriented pyrolytic carbon, and the isotropic pitchbased CFs resemble glassy carbon. Meanwhile, CFs have an axially oriented structure andconsiderably differ from natural graphite, highly oriented pyrolytic carbon, and vitreous
carbon in that the orientation of the carbon hexagonal network planes can be highly
controlled. Fig. 7 shows SEM images of anisotropic pitch-based, isotropic pitch-based,
and PAN-based CFs. All the samples used for the images are milled fibers.

Table/Figure 7. SEM images of various milled fibers:(a) anisotropic pitch-based CF (DIALEAD™/graphite thread),(b) isotropic pitch-based CF (Donacarbo/graphitized), and (c) PAN-based CF (ToraycaTM)
In the anisotropic pitch-based CF, the fibrils are folded. The differences in the degreeof holding in this folded structure likely influence the mechanical properties, such as
tensile strength and elastic modulus, and physical properties, such as thermal
conductivity. The carbon hexagonal mesh plane is selectively oriented in the fiber axis
direction, and it exhibits a high elastic modulus and high thermal conductivity in the fiber
axis direction. In the isotropic pitch-based CF, the graphite crystallinity is low, the carbon
hexagonal network plane is not developed, and the CF is not oriented. As a result, boththe cross section and side surfaces of the fiber are smooth. Therefore, the mechanicalproperties and thermal conductivity are poor. Although the PAN-based CF has low
graphite crystallinity, the carbon hexagonal mesh planes intersect and intertwine witheach other and are arranged in the fiber axis direction. Thus, the PAN-based CF exhibitshigh mechanical strength.

7Preriminary

III. Uses and demand for CFs
1. Main uses of CFs① Aircraft
CF-reinforced plastics (CFRPs) are used as an essential material for improving
fuel efficiency by reducing aircraft weight for multiple applications, e.g., those
involving primary structural materials, such as the main wings and fuselage, andsecondary structural materials, such as seats, front panels, and brake materials. In
the future, these uses are expected to expand to other parts, such as engine parts.

Table/Figure 8. Changes in CFRP usage percentage in aircraft

8

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② Wind turbine
The installed capacity of wind power has been considerably increasing since theaccident at the Fukushima Daiichi Nuclear Power Station caused by the Great East
Japan Earthquake, which triggered reviews of nuclear power policy and thermal
power generation that requires fossil fuels to realize a sustainable society. The sizeof wind-power generation blades is also increasing to improve power generation
efficiency and profitability, and further expansion of CFRP demand is expected.

Table/Figure 9. Wind power generation

9

Preriminary③ Pressure vessels
In the United States, advances in the technologies for shale gas extraction havemade the production of shale gas at low cost possible, increasing production volume
and the use of natural gas vehicles. Extraction is now being conducted in small gas
fields with insufficient infrastructure, such as natural gas pipelines, which werepreviously unprofitable. The use of CFRPs is also expanding to large compressed
natural gas (CNG) tanks used for transporting gas in these regions. CFs are also
expected to be used more widely in compressed hydrogen gas (CHG) tanks for fuelcell vehicles, which are expected to become widespread in the future, and in largepressure storage tanks for hydrogen stations.

(Source) Mitsubishi Chemical Corporation
Table/Figure 10. Pressure vessel④ Automobiles
Automobile CO2 emission regulations, such as those in Europe and Japan, arebecoming stricter each year, and automobile manufacturers are accelerating thedevelopment of hybrid, fuel-cell, natural gas, electric vehicles, etc. and their efforts
to reduce fuel and electricity consumption. CFRPs are effective at decreasing fueland electricity consumption by reducing the weight of the vehicle body. Additionally,
the CFRP tanks for filling hydrogen and natural gas described in (3) enable
increased travel distance per fuel filling owing to high compression. Furthermore,
C/C composites in which graphite is reinforced with CFs are used as electrodematerials for fuel cells.

10Preriminary

⑤ Concrete and steel infrastructure
In Japan, various types of infrastructure, such as concrete bridges, tunnels, andsteel structures built during the rapid economic growth period, are aging, and thedevelopment of countermeasures is an urgent issue.
The CF sheet fabrication method involves a sheet of on-site CF impregnated withlow-viscosity epoxy resin and hardened. This method is gaining popularity overconventional methods, such as steel plate and thickening fabrication methods,
because it does not require heavy machinery and allows repairs in a narrow space.
Furthermore, in a dedicated factory, a method has been developed for impregnating
the CF bundles with resin, hardening the bundles, and attaching the plate-shaped
CFRP to the frame. This method is expected to become more popular than the CF
sheet fabrication method because of its stability during on-site fabrication.

Table/Figure 11. Concrete reinforcement

11

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⑥ Industrial rolls, etc.
CFs have plate-like crystals with folded fiber cross sections, and they are regularly
arranged along the fiber axis direction and characterized by a high rigidity. Therefore,mechanical parts can be fabricated with a small deflection and moment of inertia anda high natural frequency. Examples include industrial rolls, liquid crystal robot hands,
industrial machine parts such as crossbars for automobile manufacturing presses,
and propeller shafts.

Table/Figure 12. Long carbon-coated roll (φ 350 × 9200 mm)

Courtesy of Corebon AB (Sweden)
Table/Figure 13. High-precision positioning robot

12

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⑦ Thermal insulation
Molded insulation is manufactured from CF felts and used in high-temperature
furnaces that ceramics and other materials cannot withstand. This molded heatinsulation is an indispensable component for silicon crystal growth furnaces used insolar cell and semiconductor manufacturing, and it reduces power consumption. It
is also widely used worldwide as a heat insulation material for high-temperature
furnaces, such as those for sapphire and silicon carbide crystal growth, ceramicsintering, optical fiber manufacturing, and graphite purification.

Table/Figure 14. Solar cells⑧ Sports and leisure applications
Sporting goods, such as fishing rods, tennis rackets, golf shafts, and bicycles, arepopular products that most effectively incorporate the specific strength and specificelastic modulus of the CF. High-performance CFs have a high demand for use infishing rods, and strength improvements in CFs have often progressed in tandemwith improvements in fishing rods. Meanwhile, wide-frame tennis rackets (so-called“thick” rackets) are revolutionary products in terms of racket functionality (lightness
and power). Additionally, for bicycles, CFs have been increasingly used in not onlyroad race bikes but also road bikes and off-road mountain bikes, such as those used
for mountain courses, which have become immensely popular. These sporting andrecreational goods are expected to remain popular in the future.

Table/Figure 15. Fishing rod

13

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2. Expected demand for CFs
Global demand for CFs increased from 42,000 tons in 2013 to approximately 90,000 tons
in 2019. Although the demand temporarily decreased owing to the impact of the novel
coronavirus infection, aircrafts, wind power generation, pressure vessels, automobiles, etc.
are expected to continue to drive the demand with global environmental action as a tailwind.
This report is based on the assumption that global CF demand will be 200,000 tons in
2030 and 500,000 tons in 2050.

Table/Figure 16. Estimated global demand for CFs

14

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IV. Global warming countermeasure efforts
1. Global warming countermeasure efforts to date
To date, the Carbon Fiber Manufacturers Association has investigated the energy
consumption and CO2 emissions at the CF manufacturing stage and quantified the CO2
emission reduction effect of CF use via LCA models for objects, such as aircraft,
automobiles, and wind turbines.
In terms of recycling, a pilot plant was constructed in Omuta City, Fukuoka Prefecturein the late 2000s as a subsidized project by the Ministry of Economy, Trade and Industryof Japan, and a demonstration study of CF recycling was conducted.

（1） CF life cycle inventory (LCI)
From FY1997 to FY1998, upon the request and guidance of the then Ministry ofInternational Trade and Industry of Japan, the Carbon Fiber Manufacturers Association
began to investigate LCI data for CFs in cooperation with the composite material LCI datafabrication project. The results were reported in the “Investigative report on the analysis
of inventory data for composite materials” (July 1999, Society of Japanese Aerospace
Companies). Subsequently, LCI data were published in FY2006, FY2009, and FY2017.
For the published values since FY2009, LCI data based on the latest production resultsin the main production line of high-strength CFs, which is the main brand of PAN-basedCFs (elastic modulus of 230–250 GPa, filament count of 12K (800 tex)–24K (1,600 tex)),were aggregated, and the results were registered with the Japan LCA Forum.
Fig. 17 shows the shifts in CO2 emissions for manufacturing 1 kg of CF, with the 2022
published value included.

Table/Figure 17. Shifts in CF LCI

15

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The investigation included the main raw materials and auxiliary raw materials/materials
used in the PAN polymerization, precursor spinning, and CF calcination processes, as wellas various utilities (electric power, water, fuel, etc.). Additionally, the main raw materials,
auxiliary raw materials, and materials used in these processes were evaluated retroactively
to the crude oil extraction stage.

Note: Range covered by performing cumulative LCI data calculation (indicated in yellow)

Table/Figure 18. Scope of calculation including retroactive analysis of the raw material
Based on these LCI data, a Carbon Fiber Manufacturers Association model of LCA for
airplanes, wind power generation, and automobiles was created, and CFs were found to be highly
effective at reducing CO2 emissions during the use stage. The Carbon Fiber Manufacturers
Association model is described in Section 2 (1) “Contributions to reducing CO2 emissions at the
product use stage.”

16

Preriminary（2） Technological development of CF recycling
In 1997, the Carbon Fiber Manufacturers Association began investigating effective disposal
methods based on the judgment that the conventional landfill disposal method could no longer
be relied upon as the CF market grew. After subsequently being entrusted with the standard
certification research and development project “Standardization of recycled carbon fiberreinforced plastic (CFRP) pulverized products” from FY2000 to FY2002 commissioned by
the New Energy and Industrial Technology Development Organization and Ministry of
Economy, Trade and Industry, the association has continued to conduct survey research anddemonstration studies on CF recycling.
Fiscal year
Around 1997

Research theme
Survey research on methods for replacing CFRP landfill disposal

NEDO-commissioned research

2000~2002

Implementing body

“Standardization of recycled CFRP pulverized products”-Development of CFRP pulverization and classification technology

Domestic PAN-based
CF manufacturer-Development of CFRP resin(thermal) decomposition/removal technology-Development of milled CF recycling technology

2003~2005

Independent research (construction of basic technology)

Subsidized project of the Ministry of Economy, Trade and Industry“Research and development of energy reduction technology

2006~2008

for CF manufacturing”-Recycling process flow design and marketability research-Pilot plant design and construction, verification of waste material recovery-Pilot plant demonstration operation, evaluation of recycled products

The Carbon Fiber
Manufacturers
Association

Joint research with Omuta City, Fukuoka Prefecture

2009~2011“Research on recycled CF”-Recycled CF manufacturing for application development project(prefecture/user)-Quality improvement of recycled, milled CFs, prototyping of short-fiber CFs
Carbon Fiber Recycling

2012~2014

Technology
Carbon Fiber Recycling Technology Development Body activities

Development Body
(domestic PAN-based
CF manufacturers)

2015~

Technological development by individual companies→commercialization

Each company

Table/Figure 19. Recycling efforts of the Carbon Fiber Manufacturers Association

17

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From 2006 to 2011, as a project subsidized by the Ministry of Economy, Trade andIndustry, a pilot plant with a processing capacity of 700 tons per year was constructed in
Eco Town in Omuta City, Fukuoka Prefecture, and a demonstration study was
conducted.

Table/Figure 20. Image of the CF recycling pilot plant (left) and diagram of the CF recycling flow(right)18

PreriminarySince FY2012, this research has been conducted by the Carbon Recycling Technology
Development Association, which was established by three PAN-based carbon
manufacturers to further develop the technology. A target of 2.6 kg CO2/kg CF was
obtained as the CO2 emission for the manufacturing of 1 kg of recycled CFs.
The Carbon Fiber Recycling Technology Development Association was dissolved in
March 2015 after it achieved its initial goal of establishing a manufacturing technology forrecycled CFs.

(Note) As of 2015

Table/Figure 21. Unit CO2 emissions during production of virgin and recycled CFs

19

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2. Long-term vision for global warming countermeasures（1） Contributions to reducing CO2 emissions at the product use stage
In this chapter, we show that CF is an excellent environmentally friendly material in termsof LCA.
The LCA is a method of calculating CO2 emissions and environmental pollutants. It is
used to scientifically, quantitatively, and objectively evaluate the numerical burden on theenvironment throughout the life cycle of a given product, from the collection of raw
materials, manufacturing, and distribution to its use in society and eventual disposal.
① Aircrafts
The application of CFRPs in aircrafts has a very large CO2 reduction effect owing to theimproved fuel efficiency. Conventionally, CFRPs have only been partially used for ailerons
and spoilers; however, expanding it to the fuselage frame, main wings, andvertical/horizontal stabilizer has enabled its use in 50% of the airframe structure. This has
provided an airframe structure that is 20% lighter and a fuel efficiency that has improved
by approximately 7%. The use of these aircrafts for 10 years can reduce CO2 emissions by
27,000 tons per aircraft.

20

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Table/Figure 22. Aircraft LCA of the “Carbon Fiber Manufacturers Association model”

21

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② Wind turbine
The use of CFRPs in wind turbine generator blades has made it possible to increase thediameter of wind turbines to over 100 m. The power generation capacity of wind turbines
is proportional to the square of the blade length; thus, the power generation capacity perunit has considerably improved, with 10-MW offshore wind power plants now being built.
If these wind turbines are used for 25 years, CO2 reductions of 318,000 tons per unit canbe achieved over that of thermal power generation (average values of coal-fired power plus
oil-fired power).

Table/Figure 23. Different offshore wind powers as a function of turbine diameter(average)

22

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Table/Figure 24. Wind turbine LCA “Carbon Fiber Manufacturers Association model”③ Automobiles
The application of CFRPs to 17% of the body weight of an average standard-sizedautomobile model can reduce its body weight by 30% compared to an automobile body thathas conventional mild steel plates on it, improving fuel consumption by 22%. The use ofthis automobile for 10 years will reduce CO2 emissions by 5 tons per automobile.

23

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Table/Figure 25. Automobile LCA “Carbon Fiber Manufacturers Association model”

24

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④ Electric vehicles
The application of CFRPs to 16% of the body weight of a mid-sized electric SUV canreduce its weight by 16% compared to a body made primarily of high-tensile steel andaluminum, and it will reduce batteries by 13%. Fuel consumption will improve, and driving
this vehicle 100,000 km in Japan or 150,000 km in Europe can reduce CO2 emissions by 2
tons per vehicle.

Table/Figure 26. Electric vehicle LCA “Carbon Fiber Manufacturers Association model”

25

Preriminary（2） Efforts to reduce CO2 emissions at the CF manufacturing stage
As mentioned above, CFs are environmentally friendly materials that considerably
contribute to energy conservation at the customer use stage. However, achieving thecarbon-neutral society advocated by the government requires further efforts to reduce CO2
emissions at the CF manufacturing stage.
Fig. 27 shows possible CO2 emission reduction measures at the CF manufacturing stage.
We have summarized our vision of how much CO2 emission can be technically reduced bythese measures during the manufacturing of 1 kg of CFs.

(Note) CCS/CCU: Abbreviation for “carbon dioxide capture and storage/utilization”
Table/Figure 27. Technologies for CO2 emission reductions during CF manufacturing

26

PreriminaryFirst, the black-dotted line in the figure shows additional industry efforts (outcomes),
such as the manufacturing process of raw CF materials (raw material mining to refining)and external procurement of utilities, including purchased electric power. Additionally, thegreen line (band) shows the effect of implementing CO2 reduction measures as intraindustry efforts, such as process improvement during CF manufacturing.
There is a wide range for the vision value because it varies depending on the market
distribution rate of recycled CFs and the status of CCS/CCU technology introduction.
Especially for CCS/CCU, one key aspect is whether the technology can be used cheaply
even in processes with relatively low CO2 concentrations.

Table/Figure 28. Vision value of unit CO2 emission during CF manufacturing
When we predicted the CO2 emissions reduction effect (outcome) that is expected when
one ton of CF is manufactured only by additional industry efforts, the results showed that
there will be a 21% decrease by 2030 and 33% decrease by 2050 (both relative to FY2013).
In addition, when one ton of CFs is manufactured, the CO2 emissions are expected to be
reduced by 30–47% by 2030 due to intra-industry efforts such as fuel conversion andprocess improvement at CF manufacturing sites and by increasing the amount of recycled
CF in circulation. Furthermore, continuing and strengthening these efforts would reduce
CO2 emissions by 78–97% by 2050 (both 2030 and 2050 values are relative to FY2013).
The slight CO2 emissions that remain are derived from the reaction products of raw
materials; thus, these emissions could be practically zero if raw materials are changed tobiologically sourced ones or introducing technologies that absorb, store, and re-use CO2(CCS/CCU).
Meanwhile, regarding the total CO2 emissions related to CF manufacturing, although theemissions are expected to increase up until approximately 2030 relative to FY2013 due to27

Preriminaryincreased demand, total CO2 emissions are expected to decrease significantly by 2050 as aresult of continuing and strengthening various energy conservation measures and byincreasing the amount of recycled CF in circulation.

（3） Recycling efforts
As of 2022, CO2 emission during the production of recycled CFs was 2.6 kg CO2/kg CF,
which was approximately one-eighth that of virgin CFs, and one effective method to reduce
CO2 emissions during CF manufacturing is to increase the market distribution of recycled
CFs.
Further developing the recycling business requires not only establishing technologies forrecycling CFs from CFRPs but also recovering CFRP waste materials, assessing the qualityof recycled CFs, and developing applications in an integrated manner. This is difficult for
the CF industry to tackle alone; thus, there is a need for the government, user industries,
recycling companies, research institutions, etc. to work together to build a business scheme.
① Amount of generated CFRP waste material and the recycled CF market
According to a Ministry of Economy, Trade and Industry survey 3 and others, asof 2020, the amount of used CFRP waste materials discharged was estimated at
46,500 tons, and the amount of CFRP waste materials discharged from the CFRP
manufacturing process was estimated at 10,500 tons. Meanwhile, less than 10%
undergoes material recycling, and most undergoes thermal recycling or ends up in alandfill.
② Recycling companies/research institutions and recycling methods worldwide
Recycled CF manufacturing technology can be broadly divided into the thermal
decomposition method (using superheated steam), liquefaction method (solvent
decomposition

method,supercritical/subcriticalfluid

method),physicalpulverization method, and electrolytic oxidation method; however, the thermal
decomposition method and its derivatives are at the stage of commercialization orpractical application.
At the end of the book, we list worldwide recycling companies (manufacturers),
recycling research institutions, and their recycling methods.

Ministry of Economy, Trade and Industry FY2021 Industrial standardization promotion

3

project consignment fund (Strategic international standardization acceleration project:
Survey research on rule formation strategy) “International trend survey on evaluation
methods and adoption status of recycled carbon fiber” (March 2022)
28

PreriminaryAn example of a thermal decomposition manufacturing process flow is shown. In
the thermal decomposition method, the recovered CFRP waste material is pulverized,
and the resin is decomposed and removed at 350–400 °C, after which the CF is
extracted. The shape of the extracted CF is diverse, including long fibers and thosethat are chopped or milled. By effectively utilizing the waste heat generated in thethermal decomposition process, it is possible to regenerate CFs with low CO2
emissions of one-eighth to one-seventh that of virgin CF.

(Source) Material Cycles and Waste Management Research, Vol. 29, No. 2, pp.
133–141, 2018
Table/Figure 29. Overview of manufacturing technology for recycled CF

Table/Figure 30. Overview of thermal decomposition method

29

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③

Test standards for recycled CF
CFRP performance is considerably affected by the performance of the CF itself,
which is the raw material. The tensile strength of recycled CFs varies considerably
depending on the regeneration conditions; thus, there is a need for a method that
can accurately evaluate the quality of recycled CFs.
Most of the JIS and ISO test standards are related to CFs and CFRP target
continuous fibers, and they are difficult to apply to recycled CFs, which containmultiple discontinuous fibers. It is our hope that CF researchers, users, andmanufacturers will work together to form a project for formulating test standards forrecycled CFs.

Table/Figure 31. Evaluation method for recycled CFs (example)

30

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④ Efforts with user industries
Although the use of CFRP parts is limited in the automobile industry, theirintroduction is expected to be promoted in the future because of weight reductionneeds.
In applying CFRP to automobiles and based on the need to establish a disposal
method in line with the Act on Recycling of End-of-Life Automobiles, in FY2019–
2021, the Carbon Fiber Manufacturers Association participated in the Appropriate
CFRP Processing Research Consortium 4 together with the Japan Automobile
Manufacturers Association, which is a user group. We investigated the appropriate
conditions for the thermal recycling of CFRP as a project of the Japan Foundation
for Advanced Auto Recycling (J-FAR).
CF, which is the raw material of CFRP, is a material that has both flame resistanceand conductivity. In one example, when an end-of-life automobile equipped with
CFRP parts became automobile shredder residue (ASR), there was the incident inwhich the inclusion of CFRP in the ASR caused problems with the processing
equipment of the ASR processing facility. Although it has not been clearly identified
that CFs are the cause, there have been requests from processing facilities for
information on how to deal with CF contamination and its combustion methods.
Given these circumstances, it was determined to be important to establish thermal
recycling technologies before the full-scale use of CFRP parts in automobiles, andthe basic combustion characteristics of CF and CFRP were determined to establish
appropriate CFRP processing methods. Simultaneously, demonstration experiments
were conducted based on the determination of these basic combustion
characteristics, and the direction of combustion treatment in existing combustion
processing facilities was set.
Additionally, preparations for simulated ASR combustion samples were advanced,
and a demonstration furnace was designed and manufactured for the demonstration
study. As a result, 97% combustion was achieved in the combustion of CFRP using
the demonstration furnace by re-injecting the combustion residue.
In this research project, it was demonstrated that CF and CFRP could be thermallyrecycled by adjusting the combustion method. Please refer to the following for thedetails.
4

Members include the Yano Research Institute, which is the project contractor, as well as the JFE

Techno-Research Corporation, Toray Research Center, Japan Automobile Manufacturers
Association, and the Japan Carbon Fiber Manufacturers Association Committee of the Japan
Chemical Fibers Association.

31

PreriminaryJapan Foundation for Advanced Auto Recycling (J-FAR)
FY2021 Independent research related to surveys, research, demonstrations, etc. that
contributes to the advancement of automobile recycling“Appropriate CFRP Treatment Research” Final Report
March 31, 2022, Yano Research Institutehttps://j-far.or.jp/project/#j

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V. Technological innovation efforts (introduction of national projects, etc.)
Various national projects have been launched to develop the basic technologies forenergy-conserving manufacturing processes of CF and CF composite materials as well as
molding in short periods of time. Each member company of the Carbon Fiber
Manufacturers Association actively participates in these national projects and plays a partin the development of basic technologies.

1. Development of innovative CF basic technologies (Innovative Structural
Materials Association (ISMA))
A complete overhaul of the current manufacturing method of PAN-based CFs wascompleted, where the acrylic fibers were made flame resistant at several hundred degrees
in air and then carbonized (calcined) at high temperature in nitrogen. The aim was toestablish a basic technology for energy conservation and highly productive
manufacturing processes.
To eliminate the flameproofing process, which is a bottleneck for improving
productivity, a solvent-soluble flame-resistant polymer was successfully synthesized forthe first time, and a basic spinning technology for 6K filaments was established. A CF
(single thread diameter of 5 µm) made from this precursor as a raw material achieved anelastic modulus of 240 GPa and elongation of 1.5%.
Meanwhile, microwave carbonization technology achieved high-speed carbonizationin seconds. Furthermore, a new method to quantitatively and precisely evaluate
differences in microwave irradiation conditions, fiber heating mechanisms, andstructural changes was found, and the basic technology to achieve stable carbonization
was developed.
One future aim is to achieve a single thread diameter of 7 µm, elastic modulus of 240
GPa, strength of 4GPa, and the completion of an industrialized process technology fora large tow (48 K).

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Table/Figure 32. Comparison between the current CF manufacturing process (PANbased) and innovative CF manufacturing process (from ISMA website)

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2. Sustainable hypercomposite technology(New Energy and Industrial Technology Development Organization(NEDO))
The following aims are outlined: develop an intermediate base material that can bemolded in a short time using CF and thermoplastic resin, high-speed molding
technology, bonding technology, and recycling technology as basic technologies forrealizing easy processing and high strengths for CF composite materials; build an
advanced energy-conserving society by further reducing the weight of automobiles andconsiderably

improvingfuelconsumption;andimprovetheinternational

competitiveness of the Japanese manufacturing industry.
① Development of an intermediate base material of an easy-to-process CF
thermoplastic resin composite (RTP)
CF surface processing technologies that achieve both high adhesion with athermoplastic resin, fiber dispersibility, and impregnation process passability,
thermoplastic resins that achieve both impregnation into CFs and physicalproperties, and isotropic/unidirectional CFRTP intermediate base materials withexcellent productivity and workability into parts have been developed.
② Development of molding technology for easy-to-process CFRTPs
High-speed stamping molding technologies and high-speed internal pressure
molding technologies will be developed as high-speed molding technologies that
use the CFRTP intermediate base material.
③ Development of bonding technology for easy-to-process CFRTPs
High-speed bonding methods with sufficient bonding strength will be
developed by various bonding types for various CFRTP components developed
via the research and development items ① and ②.
④ Development of recycling technology for easy-to-process CFRTP
Technologies that improve recyclability (performance retention rate after
recycling, number of recyclable times) and repair technologies will be developed
for various CFRTP components developed via the research and development
items ①, ②, and ③. Additionally, an environmental impact assessment (LCA)
will be conducted to quantify the degree of contribution to reducing theenvironmental impact when this developed technology is used in various
products.

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Table/Figure 33. New Energy and Industrial Technology Development Organization (NEDO)
homepage
From “Development of sustainable hypercomposite technology”

3. National Composite Center (NCC)
CFRP is a material that is expected to reduce CO2 emissions by reducing the weights
of automobile bodies. However, although general thermosetting CFRP has excellent
mechanical properties, it has issues, such as a long molding time, and its application
has been limited to aircraft and some luxury automobiles. Therefore, by focusing on
thermoplastic CFRP, which has excellent moldability and adhesion, and by applying
the long-fiber thermoplastic direct (LFT-D) method, automobile chassis parts could
be molded in approximately one minute. Furthermore, chassis assembly technologythat uses the ultrasonic fusion method has been used to successfully manufacture an
automobile chassis (10% lighter than the current aluminum chassis) made entirely ofthermoplastic CFRP for the first time in the world.

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Table/Figure 34. Conceptual diagram of the LFT-D fabrication method (from the ISMA
website)Table/Figure 35. Thermoplastic CFRP prototype chassis (from ISMA website)

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4.

Strategic Innovation Promotion Program (SIP) “Structural Materials forInnovation”(Japan Science and Technology Agency (JST))The essential requirements for advanced structural materials used in commercial
aircraft airframes and engines are that they have a low weight, low cost, high quality,and excellent productivity and maintainability. CFRP was selected for the airframe,
heat-resistant metals and ceramics were selected for the engine, and technical issues,
including those related to material development, process/processing technology, andstructural design technology, were selected.
Research domain A: Development of aircraft resins and CFRPsDevelopment of materials and their manufacturing technologies that achieve
high quality, low cost, and high productivity of main structural components(tails, wings, etc.) that can replace the existing autoclave method anddevelopment of a low-cost, high-quality (strong) autoclave prepreg for
application to main structural components (main wings, etc.)Development of a thermoplastic prepreg with excellent impact resistance andheat resistance for aircraft engine parts and molding technology andachievement of weight reduction by developing application technologies forheat-resistant polymer matrix composite material（PMC）.



Molding process monitoring of composite structures, quality assurance
technologies, non-contact/non-destructive inspection technologies, andbonding technologies

Research domain B: Development of heat-resistant alloys and intermetallic
compounds

Innovative large-scale and practical forging technologies for Ti alloys and Nibased alloys, which are the main materials for aircraft engines and power
generation turbines, and development of simulation technologies anddatabase development to support these technologies



Development of laser powder cladding technologies with excellent
workability and productivity, as well as injection molding technologies withexcellent dimensional accuracy and fatigue resistance, for application inaircraft and turbine components

Research domain C: Development of ceramic matrix composites

Practical application of heat-resistant and lightweight ceramic components is
expected to considerably improve fuel consumption and reduce CO2

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Preriminaryemissions of aircraft engines via the development of environmentally resistantcoating technologies that protect the surface of these components from hightemperature oxygen and steam environments and that enable long-term use.


Development of environment-resistant coating technologies that can beapplied to lightweight ceramic components that have both high toughness
and heat resistance

Table/Figure 36. Development of the Strategic Innovation Promotion Program (SIP)“Structural Materials for Innovation”(From the SIP “Structural Materials for Innovation” pamphlet)

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VI. Proposal to the government for low-carbonization of CFs (reduce CO2
emissions)
Measures to reduce CO2 emissions from CFs and achieve carbon neutrality pose
multiple challenges that are difficult for the CF industry alone to tackle. Requests to
the government are summarized below.
① Support for low-carbon technology development Support for the introduction of equipment that contributes to lowcarbonization/decarbonization (in-house
power generation equipment, renewable energy equipment, innovative energy
conservation/CO2 emission reduction equipment) Early establishment of power generation technology that can be implemented
using decarbonized fuels (using hydrogen, ammonia, bio-derived fuels, etc.)
 Development and social implementation of manufacturing technologies of bioderived raw materials and early technologies, such as CCS/CCU② Development of a mechanism to continually promote low carbonization
 Various types of support for the development of CF recycling businesses(collection of CFRP waste materials, quality assessment of recycled CF,
development of applications, etc.)
 Development of an internationally consistent mechanism in which society as awhole bears the costs of fuel conversion, etc.
③ Stable and cheap supply of decarbonized energy Achievement of zero emissions by 2050 for electric power supplied from electric
power companies

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VII. Conclusion
This vision includes the activities conducted to date by the Japan Carbon Fiber
Manufacturers Association Committee (formerly Carbon Fiber Manufacturers
Association) of the Japan Chemical Fibers Association and a summary of thecontributions CFs can provide even in a carbon-neutral society by formulating visions
for the future of 2030 and 2050.
CF is still called an innovative material half a century after its birth because it
constantly provides new value to the products that use it. CF has the power to change
society via its multiple excellent performances, such as weight reduction and highrigidity, which can be imparted to products. It also plays a role as a material that
protects the environment of the planet.
In a carbon-neutral society, conventional efforts needed as well as further efforts,such as countermeasures against CO2 generated at the manufacturing stage.
Expectations are focused on not only fuel conversion in the CF manufacturing process
but also the realization of a resource recycling (CF recycling) system, which should bepromoted in combination with the user industry, and the introduction of technology tocheaply absorb and re-use reaction-derived CO2, which is difficult to completely
eliminate.
We would like to ask for the continued understanding and support of the involved
parties.
End

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PreriminaryReference materials

1. CF LCI data
The most recent LCI data for virgin CFs compiled by the Carbon Fiber Manufacturers
Association (based on FY2017 production results of three PAN-based CF manufacturers)and LCI data for recycled CFs compiled by the Carbon Fiber Recycling Technology
Development Association (collected at Omuta Pilot Plant) are shown in Fig. 37.

Feedstock

EnergyCO2 emission

Energyconsumption(MJ/kg)(MJ/kg)

Virgin CF

32

319

19.8

Recycled CF

－

4６

2.6

(kg CO2/kg CF)(Note) Feedstock energy: combustion heat not used as an energy source from the input of
raw materials to the product system

Table/Figure 37. LCI data for virgin and recycled CFs

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2. Major domestic and international CFRP recycling commercialization companies and research institutions

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44Preriminary

45

Preriminary(Source) Ministry of Economy, Trade and Industry FY2020 Global warming and resource recycling countermeasures survey consignment fund “International trend
survey on the use and evaluation methods of recycled carbon fiber” (March 2021)
Table/Figure 38. Recycling methods implemented by CF recycling companies (manufacturers) and research institutions worldwide

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Preriminary3. Framework for carbon neutrality by the Carbon Fiber Manufacturers
Association
The framework and responsibilities for carbon neutrality at the Carbon Fiber
Manufacturers Association Committee are summarized below.
Corresponding organization
CF Technology Committee
CF Sustainability Vision
Working Group

Content
General technologies related to CF
REACH-compliant
Creation, dissemination, and revision of a vision
for carbon neutrality in the CF industry
LCA of CFs

LCA Subcommittee

LCI data survey
Additions and revisions to the Carbon Fiber
Manufacturers Association modelStandardization of recycled CFs

Standardization subcommittee(Reference) measures by eachcompany

Standardization of testing methods for recycled
CFs
Energy sector measures
Manufacturing sector measures
Recycling

Table/Figure 39. Framework for carbon neutrality by the Carbon Fiber Manufacturers
Association Committee

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Table/Figure 40. Organizational chart of the Japan Carbon Fiber Manufacturers Association
Committee, Japan Chemical Fibers Association

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