Title Presentation - Harper International · 2002 2004 2006 2008 2010 2012 2014 2016. Tousands of...

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Courtesy of Oak Ridge National Laboratory

Courtesy of Georgia Institute of Technology

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Courtesy of Oak Ridge National Laboratory

Courtesy of Georgia Institute of Technology

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2002 2004 2006 2008 2010 2012 2014 2016

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Carbon Fiber - Global CF Capacity

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Source: http://www.aluminiumleader.com/economics/world_market/

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Source: https://www.worldsteel.org/Steel-markets/Automotive.html/

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Carbon Fiber - Global CF Capacity Aluminum - Global AutomotiveIndustry Consumption

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1970 1980 1990 2000 2010 2020 2030

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USA Corporate Average Fuel Economy Mandates

1975-2025

All Cars 1978-2011

Small Cars 2011-2025

Big Cars 2012-2025

Source: National Highway Traffic Safety Administration, http://www.nhtsa.gov/fuel-economy

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1970 1980 1990 2000 2010 2020 2030

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USA Corporate Average Fuel Economy Mandates

1975-2025

All Cars 1978-2011

Small Cars 2011-2025

Big Cars 2012-2025

Actuals

Source: National Highway Traffic Safety Administration, http://www.nhtsa.gov/fuel-economy

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1970 1980 1990 2000 2010 2020 2030

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Man

dat

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Fu

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y (m

pg)

USA Corporate Average Fuel Economy Mandates

1975-2025

All Cars 1978-2011

Small Cars 2011-2025

Big Cars 2012-2025

Actuals

Aluminum Per Vehicle

Source: 2015 North American Light Vehicle Aluminum Content Study, Ducker Worldwide, 2014

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Image © General Motors

Carbon Fiber

Sources: plasancarbon.com; corvetteblogger.com; GM, Ford, and VW Annual Reports

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Image © General Motors

Carbon Fiber

Sources: plasancarbon.com; corvetteblogger.com; GM, Ford, and VW Annual Reports

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Image © General Motors

Carbon Fiber

Sources: plasancarbon.com; corvetteblogger.com; GM, Ford, and VW Annual Reports

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Image © General Motors

Carbon Fiber

Sources: plasancarbon.com; corvetteblogger.com; GM, Ford, and VW Annual Reports

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Image © General Motors

What If

Carbon Fiber

Sources: plasancarbon.com; corvetteblogger.com; GM, Ford, and VW Annual Reports

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Image © General Motors

2014 General Motors

• 6.03 Million Vehicles

What If

Carbon Fiber

Sources: plasancarbon.com; corvetteblogger.com; GM, Ford, and VW Annual Reports

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Image © General Motors

2014 General Motors

• 6.03 Million Vehicles

49,000 Tons CF

What If

Carbon Fiber

Sources: plasancarbon.com; corvetteblogger.com; GM, Ford, and VW Annual Reports

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Image © General Motors

2014 General Motors

• 6.03 Million Vehicles

49,000 Tons CF

2014 Ford

• 6.3 Million Vehicles

What If

Carbon Fiber

Sources: plasancarbon.com; corvetteblogger.com; GM, Ford, and VW Annual Reports

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Image © General Motors

2014 General Motors

• 6.03 Million Vehicles

49,000 Tons CF

2014 Ford

• 6.3 Million Vehicles

51,000 Tons CF

What If

Carbon Fiber

Sources: plasancarbon.com; corvetteblogger.com; GM, Ford, and VW Annual Reports

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Image © General Motors

2014 General Motors

• 6.03 Million Vehicles

49,000 Tons CF

2014 Ford

• 6.3 Million Vehicles

51,000 Tons CF

2014 Volkswagen AG

• 10.1 Million Vehicles

What If

Carbon Fiber

Sources: plasancarbon.com; corvetteblogger.com; GM, Ford, and VW Annual Reports

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Image © General Motors

2014 General Motors

• 6.03 Million Vehicles

49,000 Tons CF

2014 Ford

• 6.3 Million Vehicles

51,000 Tons CF

2014 Volkswagen AG

• 10.1 Million Vehicles

82,000 Tons CF

What If

Carbon Fiber

Sources: plasancarbon.com; corvetteblogger.com; GM, Ford, and VW Annual Reports

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Image © General Motors

2014 General Motors

• 6.03 Million Vehicles

49,000 Tons CF

2014 Ford

• 6.3 Million Vehicles

51,000 Tons CF

2014 Volkswagen AG

• 10.1 Million Vehicles

82,000 Tons CF

2014 Global Industry

• 87.9 Million Vehicles

What If

Carbon Fiber

Sources: plasancarbon.com; corvetteblogger.com; GM, Ford, and VW Annual Reports

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Image © General Motors

2014 General Motors

• 6.03 Million Vehicles

49,000 Tons CF

2014 Ford

• 6.3 Million Vehicles

51,000 Tons CF

2014 Volkswagen AG

• 10.1 Million Vehicles

82,000 Tons CF

2014 Global Industry

• 87.9 Million Vehicles

718,000 Tons CF

What If

Carbon Fiber

Sources: plasancarbon.com; corvetteblogger.com; GM, Ford, and VW Annual Reports

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Image © General Motors

2014 General Motors

• 6.03 Million Vehicles

49,000 Tons CF

2014 Ford

• 6.3 Million Vehicles

51,000 Tons CF

2014 Volkswagen AG

• 10.1 Million Vehicles

82,000 Tons CF

2014 Global Industry

• 87.9 Million Vehicles

718,000 Tons CF

What If

Carbon Fiber

Sources: plasancarbon.com; corvetteblogger.com; GM, Ford, and VW Annual Reports

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DRIVES 4&5PRECURSORMOISTENING

DRIVE 1

VENT TO RTO (VE)MAKE-UP AIR (MA)

THERMAL OXIDIZER

CREEL STATION OXIDATION OVEN STACK 1 DRIVE 7DRIVE 6DRIVES 2&3OXIDATION OVEN STACK 2 OXIDATION OVEN STACK 3

DRIVE 9DRIVE 8 ONLINE WINDING SURFACE TREATMENT SYSTEMHT FURNACE SYSTEMLT FURNACE SYSTEM

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𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝑅𝑎𝑡𝑒

= 𝑌𝑖𝑒𝑙𝑑 × 𝑀𝑎𝑠𝑠

𝐹𝑖𝑙𝑎𝑚𝑒𝑛𝑡 𝐿𝑒𝑛𝑔𝑡ℎ × 𝑇𝑜𝑡𝑎𝑙 𝐹𝑖𝑙𝑎𝑚𝑒𝑛𝑡𝑠 × (𝐿𝑖𝑛𝑒𝑠𝑝𝑒𝑒𝑑)

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𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝑅𝑎𝑡𝑒

= 𝑌𝑖𝑒𝑙𝑑 × 𝑀𝑎𝑠𝑠

𝐹𝑖𝑙𝑎𝑚𝑒𝑛𝑡 𝐿𝑒𝑛𝑔𝑡ℎ × 𝑇𝑜𝑡𝑎𝑙 𝐹𝑖𝑙𝑎𝑚𝑒𝑛𝑡𝑠 × (𝐿𝑖𝑛𝑒𝑠𝑝𝑒𝑒𝑑)

𝑇𝑜𝑡𝑎𝑙 𝐹𝑖𝑙𝑎𝑚𝑒𝑛𝑡𝑠 =𝐹𝑖𝑙𝑎𝑚𝑒𝑛𝑡𝑠

𝑊𝑖𝑑𝑡ℎ× (𝐿𝑖𝑛𝑒𝑤𝑖𝑑𝑡ℎ)

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𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝑅𝑎𝑡𝑒

= 𝑌𝑖𝑒𝑙𝑑 × 𝑀𝑎𝑠𝑠

𝐹𝑖𝑙𝑎𝑚𝑒𝑛𝑡 𝐿𝑒𝑛𝑔𝑡ℎ × 𝑇𝑜𝑡𝑎𝑙 𝐹𝑖𝑙𝑎𝑚𝑒𝑛𝑡𝑠 × (𝐿𝑖𝑛𝑒𝑠𝑝𝑒𝑒𝑑)

𝑇𝑜𝑡𝑎𝑙 𝐹𝑖𝑙𝑎𝑚𝑒𝑛𝑡𝑠 =𝐹𝑖𝑙𝑎𝑚𝑒𝑛𝑡𝑠

𝑊𝑖𝑑𝑡ℎ× (𝐿𝑖𝑛𝑒𝑤𝑖𝑑𝑡ℎ)

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𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝑅𝑎𝑡𝑒

= 𝑌𝑖𝑒𝑙𝑑 × 𝑀𝑎𝑠𝑠

𝐹𝑖𝑙𝑎𝑚𝑒𝑛𝑡 𝐿𝑒𝑛𝑔𝑡ℎ × 𝑇𝑜𝑡𝑎𝑙 𝐹𝑖𝑙𝑎𝑚𝑒𝑛𝑡𝑠 × (𝐿𝑖𝑛𝑒𝑠𝑝𝑒𝑒𝑑)

𝑇𝑜𝑡𝑎𝑙 𝐹𝑖𝑙𝑎𝑚𝑒𝑛𝑡𝑠 =𝐹𝑖𝑙𝑎𝑚𝑒𝑛𝑡𝑠

𝑊𝑖𝑑𝑡ℎ× (𝐿𝑖𝑛𝑒𝑤𝑖𝑑𝑡ℎ)

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* Source: ORNL Low-Cost Carbon Fiber Process – April, 2016

Filaments per mm

Linewidth m

Linespeed m/min Tonnes/year

Baseline 2000 3 10 2000

Scaleup Factor 1.71 1.71 1.71 5 3420 5.13 17.1 10000

Scaleup Factor 1.25 2.00 2.00 5 2500 6.00 20.0 10000

Scaleup Factor 1.75 2.00 1.43 5 3500 6.00 14.3 10000

Scaleup Factor 4.50 1.00 1.11 5 9000* 3.00 10.5 10000

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* Source: ORNL Low-Cost Carbon Fiber Process – April, 2016

Filaments per mm

Linewidth m

Linespeed m/min Tonnes/year

Baseline 2000 3 10 2000

Scaleup Factor 1.71 1.71 1.71 5 3420 5.13 17.1 10000

Scaleup Factor 1.25 2.00 2.00 5 2500 6.00 20.0 10000

Scaleup Factor 1.75 2.00 1.43 5 3500 6.00 14.3 10000

Scaleup Factor 4.50 1.00 1.11 5 9000* 3.00 10.5 10000

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* Source: ORNL Low-Cost Carbon Fiber Process – April, 2016

Filaments per mm

Linewidth m

Linespeed m/min Tonnes/year

Baseline 2000 3 10 2000

Scaleup Factor 1.71 1.71 1.71 5 3420 5.13 17.1 10000

Scaleup Factor 1.25 2.00 2.00 5 2500 6.00 20.0 10000

Scaleup Factor 1.75 2.00 1.43 5 3500 6.00 14.3 10000

Scaleup Factor 4.50 1.00 1.11 5 9000* 3.00 10.5 10000

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Today Tomorrow 2,000 TPY 10,000 TPY 3 meters wide 5 or 6 meters wide 10 m/min 20 m/min 2,500 filaments/mm 5,000 filaments/mm

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Today Tomorrow 2,000 TPY 10,000 TPY 3 meters wide 5 or 6 meters wide 10 m/min 20 m/min 2,500 filaments/mm 5,000 filaments/mm

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Today Tomorrow 2,000 TPY 10,000 TPY 3 meters wide 5 or 6 meters wide 10 m/min 20 m/min 2,500 filaments/mm 5,000 filaments/mm

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Today Tomorrow 2,000 TPY 10,000 TPY 3 meters wide 5 or 6 meters wide 10 m/min 20 m/min 2,500 filaments/mm 5,000 filaments/mm

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Today Tomorrow 2,000 TPY 10,000 TPY 3 meters wide 5 or 6 meters wide 10 m/min 20 m/min 2,500 filaments/mm 5,000 filaments/mm

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Today Tomorrow 2,000 TPY 10,000 TPY 3 meters wide 5 or 6 meters wide 10 m/min 20 m/min 2,500 filaments/mm 5,000 filaments/mm

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Today Tomorrow 2,000 TPY 10,000 TPY 3 meters wide 5 or 6 meters wide 10 m/min 20 m/min 2,500 filaments/mm 5,000 filaments/mm

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Today Tomorrow 2,000 TPY 10,000 TPY 3 meters wide 5 or 6 meters wide 10 m/min 20 m/min 2,500 filaments/mm 5,000 filaments/mm

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Today Tomorrow 2,000 TPY 10,000 TPY 3 meters wide 5 or 6 meters wide 10 m/min 20 m/min 2,500 filaments/mm 5,000 filaments/mm

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Today Tomorrow 2,000 TPY 10,000 TPY 3 meters wide 5 or 6 meters wide 10 m/min 20 m/min 2,500 filaments/mm 5,000 filaments/mm

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Today Tomorrow 2,000 TPY 10,000 TPY 3 meters wide 5 or 6 meters wide 10 m/min 20 m/min 2,500 filaments/mm 5,000 filaments/mm

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Today Tomorrow 2,000 TPY 10,000 TPY 3 meters wide 5 or 6 meters wide 10 m/min 20 m/min 2,500 filaments/mm 5,000 filaments/mm

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Today Tomorrow 2,000 TPY 10,000 TPY 3 meters wide 5 or 6 meters wide 10 m/min 20 m/min 2,500 filaments/mm 5,000 filaments/mm

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Today Tomorrow 2,000 TPY 10,000 TPY 3 meters wide 5 or 6 meters wide 10 m/min 20 m/min 2,500 filaments/mm 5,000 filaments/mm

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Today Tomorrow 2,000 TPY 10,000 TPY 3 meters wide 5 or 6 meters wide 10 m/min 20 m/min 2,500 filaments/mm 5,000 filaments/mm

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Today Tomorrow 2,000 TPY 10,000 TPY 3 meters wide 5 or 6 meters wide 10 m/min 20 m/min 2,500 filaments/mm 5,000 filaments/mm

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Today Tomorrow 2,000 TPY 10,000 TPY 3 meters wide 5 or 6 meters wide 10 m/min 20 m/min 2,500 filaments/mm 5,000 filaments/mm

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Today Tomorrow 2,000 TPY 10,000 TPY 3 meters wide 5 or 6 meters wide 10 m/min 20 m/min 2,500 filaments/mm 5,000 filaments/mm

Overall needs…

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Today Tomorrow 2,000 TPY 10,000 TPY 3 meters wide 5 or 6 meters wide 10 m/min 20 m/min 2,500 filaments/mm 5,000 filaments/mm

Overall needs…

Greater process stability

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Today Tomorrow 2,000 TPY 10,000 TPY 3 meters wide 5 or 6 meters wide 10 m/min 20 m/min 2,500 filaments/mm 5,000 filaments/mm

Overall needs…

Greater process stability

Equipment thermal precision and reliability

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“Like toasting a marshmallow on a camp fire.”

-Dr. Renee Bagwell

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“Like toasting a marshmallow on a camp fire.”

-Dr. Renee Bagwell

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“Like toasting a marshmallow on a camp fire.”

-Dr. Renee Bagwell

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“Like toasting a marshmallow on a camp fire.”

-Dr. Renee Bagwell

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“Like toasting a marshmallow on a camp fire.”

-Dr. Renee Bagwell

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OVEN 1 OVEN 2 OVEN 3LT HT

SURFACE

TREATMENT

RTO HX1 HX2 DFTO HX3

HOOD FLOWS

DRYERS OVENS EXHAUST

MAKEUP

AIR

DUST COLLECTOR STACK

FURNACES EXHAUST

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OVEN 1 OVEN 2 OVEN 3LT HT

SURFACE

TREATMENT

RTO HX1 HX3DFTO HX2

HOOD FLOWS

DRYERS OVENS EXHAUST OVENS

MAKEUP

AIR

DUST COLLECTOR STACK

FURNACES

EXHAUST

NITROGEN

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Carbon Fiber -Global CF Capacity

Aluminum - GlobalAutomotive

IndustryConsumption

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IndustryConsumption

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Carbon Fiber -Global CF Capacity

Aluminum - GlobalAutomotive

IndustryConsumption

Steel - GlobalAutomotive

IndustryConsumption

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Reduced CAPEX / Depreciation

Reduced Labor

Reduced energy consumption

Reduced $/kgCF

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Carbon Fiber -Global CF Capacity

Aluminum - GlobalAutomotive

IndustryConsumption

Steel - GlobalAutomotive

IndustryConsumption

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Reduced CAPEX / Depreciation

Reduced Labor

Reduced energy consumption

Reduced $/kgCF

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