Carbon Fibre Grand Challenge

*The term “bitumen” is used throughout this web page and in Carbon Fibre Grand Challenge documentation. Bitumen is the heavy oil extracted from Alberta’s oil sands. No exceptions will be made to this definition. There are other definitions for bitumen around the world but those definitions do not apply for the purposes of the Carbon Fibre Grand Challenge.

**Application process updated. Applicants will need to deliver a presentation to the review committee during the week of August 21-25, 2023. Exact presentation dates and times will be confirmed after the application period closes on June 26, 2023.

The Carbon Fibre Grand Challenge (‘CFGC’) is a $26 million three-phase competition with the objective of accelerating the development of large-scale production pathways for short and continuous carbon fibre from bitumen-derived feedstocks and promoting their use in manufactured products.

The CFGC is part of the Bitumen Beyond Combustion (BBC) initiative by Alberta Innovates to further the development of non-combustion products, and their production technologies, derived from bitumen contained in Alberta’s oil sands. The latter are amongst the world’s largest hydrocarbon resources, with proven reserves of approximately 170 billion barrels and current production of 3 million barrels per day. At present, most bitumen products are destined for energy generation by combustion (such as gasoline, diesel, and heating oil).

Carbon Fibre (‘CF’) is one of the identified products that could be made from bitumen. The high strength and stiffness of CF, coupled with low density and high corrosion resistance, along with desirable functional properties (e.g. thermal or electrical conductivity) make composite materials that incorporate CF functionally superior to many conventional metals, wood products, and commercial polymers for use in electric vehicles, transportation, infrastructure, construction, and consumer products sectors. Alberta Innovates is working with CF manufacturers and end users, who have been providing market information and target performance specifications. Current demand for carbon fibre is constrained by the high costs of feedstocks and production technologies (primarily based on polyacrylonitrile or pitch) and incorporating fibre into mass produced end-products, like automobile components.

The Carbon Fibre Grand Challenge Phase III program is directed towards funding the development of technologies that can convert feedstocks derived from Alberta’s oil sands into CF. These feedstocks should be produced, or have the potential to be produced, in large enough quantities to supply a large-scale carbon fibre industry. These feedstocks may include, but are not limited to, asphaltenes[1] and refinery feeds. The price of asphaltene or refinery derived feedstocks from Alberta bitumen are projected to be significantly lower than polyacrylonitrile ($2 – 5 USD / lb) feedstocks.

Carbon fibre from bitumen-derived asphaltenes is estimated to have significantly smaller environmental impacts than CF produced from other sources, including agriculture and forestry. Oil sands operators, CF producers and end users have expressed significant interest in carbon fibre derived from bitumen provided performance and cost criteria can also be met.

[1] Asphaltenes are defined as the fraction of the bitumen that is soluble in toluene and insoluble in n-alkane solvents. Because they are defined by solubility, there is no single molecule, chemical composition or structure that defines an “asphaltene”.

Rationale

The Carbon Fibre Grand Challenge aims to produce new carbon fibre products and processes, reduce lifecycle GHG emissions of carbon fibres and aid in the economic diversification of Alberta. There exists significant potential to increase the value of Alberta bitumen and grow Alberta’s green economy, all while increasing employment and export potential.

Program Details

The full Program Guide will be released in early May 2023. There are three phases to the CFGC.  Phase I concluded in February 2021. Phase II will conclude in July 2023. Phase III Applications will open on May 15, 2023. Applicants to Phase III are not required to have participated in Phases I or II.

Phase III: September 2023 – August 2026

• Applicant Objectives:
  • In a repeatable manner, manufacture carbon fibre from Alberta bitumen derived feeds with consistent performance properties aligned to market needs.
  • Incorporate carbon fibre manufactured in Phase III into prototypes of end use products and evaluate/validate the performance of the prototypes.
  • Understand in great detail the environmental impacts of the manufacturing process and the techno-economics associated with the designed process.
• Targeted Outcomes:
  • Continuous & repeatable carbon fibre manufacture of >1 kg per week with consistent performance properties over a period of time that allows for the understanding of the environmental impacts and waste streams associated with the manufacturing process.
  • A minimum tensile strength >1,720 MPa and modulus >172 GPa or other strength/modulus combination that meets commercial needs and can be demonstrated through end user performance requirements.
  • Projected commercial cost of carbon fibre <US$9 per kg or a demonstrated carbon fibre cost-performance relationship that is at least 50% less expensive than incumbent competitors.
  • Line-of-sight to scale carbon fibre manufacturing process to 2000 tonnes or greater per year.
  • Demonstrated market potential of products incorporating carbon fibre, utilizing >10,000 tonnes per year of bitumen derived feedstock by 2030.
  • Building a small-scale prototype of an end product(s) (e.g. test parts) that include(s) carbon fibre.
  • Potential of mass manufacture of identified end use products(s) identified above, concepts for their re-use and end-of-life disposition.
  • Estimate of lifecycle greenhouse gas emissions and other socio/environmental impacts of the carbon fibre and their products;
• Funding: $200,001 up to $4,000,000 CAD awarded to successful applicants. A total of $20,000,000 CAD is available.  Following a modest initial payment, funding will be provided on a reimbursement basis as milestones are achieved as the project progresses.  Milestones are aligned with the project implementation plan. Alberta Innovates is working with partners to support Phase III of the CFGC. Funding partners will be confirmed with the full Program Guide release in early May along with additional funding rules related to stacking and eligible/ineligible costs.
• Application Deadline: June 26, 2023, at 2:00 PM MDT
• Funding Decision Notification: July 2023
• Earliest Project Start Date: September 1, 2023