Carbon
fibers are materials of paramount importance for composites
applied in fields such as aerospace engineering, medicine, and renewable
energy. Currently, most of the production of carbon fibers uses polyacrylonitrile,
which incurs significant greenhouse gas emissions and high production
costs. Therefore, carbon fiber manufacturing from asphaltene-enriched
feedstocks is attractive as it could add value to extra-heavy fossil
fuels and cut down precursor costs by ∼90%. Recent studies
indicate that some asphaltene-rich samples feature rheological properties
that make them optimal for melt-spinning and carbon fiber production;
in other cases, the spun asphaltene feedstocks are unsuitable for
such applications. In this work, bitumen asphaltenes were subjected
to upgrading processes under three distinctive conditions to tweak
their rheological properties in order to produce carbon fibers. The
treated samples were comprehensively studied by separations based
on solubility and extrography, and subsequently characterized by ultrahigh-resolution
mass spectrometry, gas-phase fragmentation, and thermogravimetric
analysis. The results indicate that upon thermal processing, asphaltene-rich
feedstocks produced a mixture with diverse solubility, i.e., maltenes,
asphaltenes, and toluene-insoluble material. The molecular composition
of remnant asphaltenes suggests that thermal treatment dramatically
decreased molecular polydispersity in terms of the content of heteroatoms,
alkyl chains, and structural motifs, i.e., single-core vs multicore,
also known as island vs archipelago. The processed asphaltenes revealed
high abundances of alkyl-depleted island species. Such thermally treated
samples produced no stable carbon fibers. Conversely, a feedstock
treated with molten sodium in a proprietary process designed to remove
sulfur, revealed increased content of alkyl-side chains and archipelago
structural motifs. This sample produced stable carbon fibers. Furthermore,
thermal analysis coupled with mass spectrometry (TGA-HRMS) was conducted
to understand thermal desorption and pyrolysis profiles for the samples,
as well as the presence of occluded compounds and carbon residue formation.
The TGA-HRMS results are consistent with extrography and IRMPD FT-ICR
MS studies and confirmed the ultrahigh abundance of multicore compounds
in the desulfurized sample. Although the sample size is limited, and
thus, correlations between molecular composition and rheology properties
are not achieved, this is the first study that aims to understand
the role of feed composition in the ability to generate carbon fibers
from asphaltene-enriched feedstocks. Collectively, the results indicate
that samples comprised of abundant highly aromatic asphaltenes, dominant
in alkyl-depleted single-core structures, are unlikely optimal for
carbon fiber applications. Conversely, a sample with a marked increase
in H/C, a significant decrease in S content, and abundant multicore
species could generate stable carbon fibers. More studies are underway
to find correlations ...