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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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Carbon Fiber - Global CF Capacity
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Material Comparisons
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Source: http://www.aluminiumleader.com/economics/world_market/
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Carbon Fiber - Global CF Capacity Aluminum - Global AutomotiveIndustry Consumption
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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
Steel - Global Automotive IndustryConsumption
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Material Comparisons
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1970 1980 1990 2000 2010 2020 2030
Man
dat
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Fu
el E
con
om
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pg)
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
Man
dat
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Fu
el E
con
om
y (m
pg)
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
Alu
min
um
(kg
/ve
hic
le)
Man
dat
ed
Fu
el E
con
om
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)
35
𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝑅𝑎𝑡𝑒
= 𝑌𝑖𝑒𝑙𝑑 × 𝑀𝑎𝑠𝑠
𝐹𝑖𝑙𝑎𝑚𝑒𝑛𝑡 𝐿𝑒𝑛𝑔𝑡ℎ × 𝑇𝑜𝑡𝑎𝑙 𝐹𝑖𝑙𝑎𝑚𝑒𝑛𝑡𝑠 × (𝐿𝑖𝑛𝑒𝑠𝑝𝑒𝑒𝑑)
𝑇𝑜𝑡𝑎𝑙 𝐹𝑖𝑙𝑎𝑚𝑒𝑛𝑡𝑠 =𝐹𝑖𝑙𝑎𝑚𝑒𝑛𝑡𝑠
𝑊𝑖𝑑𝑡ℎ× (𝐿𝑖𝑛𝑒𝑤𝑖𝑑𝑡ℎ)
36
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
Steel - GlobalAutomotive
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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Material Comparisons
Reduced CAPEX / Depreciation
Reduced Labor
Reduced energy consumption
Reduced $/kgCF
87
