Shell–core structured carbon fibers via melt spinning of petroleum- and wood-processing waste blends

In the last decades, carbon fibers with light weight and high strength have experienced the largely increased uses in various industrial applications. However, their expected uses in the automotive industry and building are largely limited because of their high production cost. Herein, we have demonstrated an effective method of making low cost carbon fibers via the melt spinning of petroleum-processing residue (pyrolyzed fuel oil, PFO)/lignin blends. Careful selection of tetrahydrofuran as the solvent to dissolve both PFO and lignin was made to optimize the miscible blend. The melt spinnable blend with a softening point of 260–280 °C exhibited good spinning ability at 280 °C. The plasticizing function of PFO allowed the highly cross linked lignin-based pitch to have high fluidity in the melt spinning process. Based on detailed TEM observations, the thermally treated fiber prepared at 2800 °C exhibited a shell–core structure, consisting of a highly crystalline surface from PFO and an amorphous disordered core from lignin. Such a crystalline surface structure gave rise to a high modulus value (up to 100 GPa) to the prepared carbon fibers.