Over the past 25 years, Green Chemistry has provided a unique forum for the publication of innovative research on the development of alternative sustainable technologies, efficient utilisation of resources and the concomitant minimisation of waste. We are delighted to bring together a very special issue containing articles by members of the green chemistry community as well as past and present Green Chemistry Board members, to mark and celebrate our first 25 years.
Among the contributions to this themed collection is a Paper on the production of low-cost high-quality carbon fiber using lignin alone without chemical treatment or additives (DOI: 10.1039/D3GC04288J).
Read our interview with Xianglan Bai, the corresponding author.
Could you briefly explain the focus of your article to the non-specialist
Low-cost green carbon fiber is of great interest due to its ability to improve material performance and decarbonize industries. For example, broader applications of low-cost carbon fiber in the automobile industry can improve fuel efficiency and reduce carbon emissions from the transportation sector. The US Department of Energy (DOE) stated in the early 2000s that carbon fiber with a tensile strength of 1.72 GPa and tensile modulus of 172 GPa at costs below $5-7/lb can be widely used in the automobile industries. Although lignin has been considered the most promising low-cost green precursor of carbon fiber, the major bottleneck and barrier in developing commercially relevant lignin-based carbon fibers is their poor mechanical properties far below the commercial petroleum-based carbon fibers. Previous approaches of chemically modifying lignin or processing lignin and co-precursors were ineffective in meeting the cost and property requirements of carbon fiber. We recently discovered a surprisingly simple and low-cost method to improve the tensile properties of lignin-based carbon fiber. By integrating thermal heating and tension stretching during the carbon fiber processing, we successfully manipulated the intrinsic lignin chemistry and controlled material transformation. Our melt-spun carbon fiber made of unmodified raw lignin achieved unprecedented mechanical properties compared to previous lignin-based carbon fiber (tensile strength of 2.45 GPa and tensile modulus of 236 GPa). Its production cost was only $4.17/lb, suggesting its promising economic potential.
How would you set this article in a wider context?
In addition to traditional pulping industries, lignin is increasingly available as a low-cost byproduct from emerging biorefineries. Developing lignin-based high-value products with market-comparable scale holds the key to the economic sustainability of biorefineries. Lignin-based green carbon fiber can be attractive due to its enormous potential markets, such as the automobile and construction industries. However, previous approaches for producing lignin-based carbon fiber have been mostly unsuccessful due to the poor properties of the resultant carbon fibers. Thanks to the thermo-mechanochemistry of lignin discovered in our recent work, 100% lignin-based carbon fibers meeting the automobile-grade properties and cost requirements were achieved by simply controlling heat and tension applied during carbon fiber processing. The discovery of the novel chemistry of lignin and our proof-of-concept results will alter perceptions of lignin-based carbon fibers as the commercially viable low-cost green carbon fibers, therefore advancing lignin valorization in biorefineries.
What is the motivation behind this work?
Polyacrylonitrile, the standard carbon fiber precursor, has one dimensional repeated polymer structure. During its stabilization and carbonization process, the well-defined structure of polyacrylonitrile transforms into a highly oriented turbostratic graphene structure that offers exceptionally high mechanical properties. In comparison, lignin is an amorphous polymer with three-dimensional crosslinked network. During the conventional stabilization and carbonization process, the non-oriented lignin structure turns into an amorphous carbon structure with pores, which leads to poor mechanical properties. Because the intrinsic lignin structure lacking in molecular orientation is responsible for the poor mechanical properties of lignin-based carbon fiber, previous approaches mainly focused on chemically modifying lignin or blending lignin with other polymers or additives with well-defined linear structures. However, such efforts for modifying precursors were insufficient to overcome the tensile property issues of the carbon fiber.
Lignin undergoes extensive chemical transformation and microstructural changes during the thermal treatments required for producing carbon fiber. Thus, it may be possible to alter the chemical reactions of lignin and microstructural evolution through controlling the fiber processing conditions. However, this potential opportunity for modifying lignin has been largely overlooked. In previous studies, lignin-based precursors were oxidized and carbonized using empirical methods or the method initially developed for petroleum-based precursors. To address the knowledge gap, we carefully tracked the chemical structure and corresponding microstructural formation through various stages of fiber fabrication under different thermal and tension conditions. As a result, we found that combining proper thermal treatment and strong tension stretching of the fiber can manipulate chemical reactions and control the microstructure evolution, transforming lignin into oriented and graphene carbons at a surprisingly low temperature of 700 ℃. Based on our patent-pending fiber processing method tailored for lignin, high-quality carbon fiber can be obtained without needing costly co-precursors or chemical treatment.
What aspects of this work are you most excited about at the moment and what do you find most challenging about it?
The discovery of lignin’s thermo-mechanochemistry in our work will provide many exciting opportunities for converting lignin into interesting and higher-value products. Thermo-mechanochemistry is a new terminology our group invented for lignin, which was previously unknown. Since lignin structure depends on parent biomass origin and lignin extraction methods, more research is required to fully understand this new chemistry of lignin. Combining advanced analytical techniques and computational studies will help understand a novel material chemistry.
What is the next step? What work is planned?
We plan to expand our current research to investigate broader types of lignin. We will improve our understanding of lignin’s thermo-mechanochemistry by developing the structure-process-property relationships for different lignin and precursors. We will also continue to improve our methods to increase the mechanical properties of the carbon fiber and reduce production costs. We hope to collaborate with industries to demonstrate our carbon fiber processing method in scale and utilize lignin produced from different industrial processes.
Please describe your journey to becoming part of the Green Chemistry community
I began my academic career as an assistant professor at Iowa State University in 2013. Since then, the overarching goal of my research group has been developing environmentally friendly and transformative technologies to valorize low-cost, abundant resources. Over the years, our group has developed broader expertise in thermochemical conversion, electrified conversion, and material synthesis to convert biomass, waste plastics, and greenhouse gases into fuels, chemicals, and carbon materials. Studying various technologies and feedstocks allowed us to gain expertise in developing integrated processes and multidisciplinary approaches for solving challenging problems in sustainability. In this work, we combined our knowledge of lignin chemistry and material science to investigate lignin-based carbon fiber, which led to the discovery of a novel material chemistry and a new lignin-tailored process for carbon fiber production.
Why did you choose to publish in Green Chemistry?
Green Chemistry is known for publishing high-quality frontier research on various sustainability topics. In this context, Green Chemistry has always been among the top choices to publish our research. Our group has a long history of publishing in Green Chemistry.
What do you think the Green Chemistry journal has done well in the past 25 years, and what do you think are the main challenges our community will face in the next 25 years?
Green Chemistry journal has been widely recognized as one of the top journals in sustainability research. The journal has published many exciting and groundbreaking research. As environmental and energy issues remain grand challenges for our society, there is no doubt that Green Chemistry will continue to serve as an important platform for communicating scientific discoveries in the broader realms of sustainability. In terms of future challenges, improving the transformative aspect of the research findings to demonstrate technologies in scale and developing system approaches is strongly desired for the novel research to make a real-world impact.
Meet the corresponding author
Xianglan Bai is currently a Professor of Mechanical Engineering at Iowa State University. She is also a courtesy professor of Chemical and Biological Engineering at the same institution. She is the Editorial Board Member of Fuel Processing Technology and Carbon Neutrality. The focus of her research group is the valorization of biomass and waste plastics into fuels, chemicals, and carbon-based materials via developing novel thermochemical conversion, electrified conversion (non-thermal plasma and joule heating), and material synthesis.