There is an increasing demand for lightweight composites reinforced with carbon fibers (CFs). Due to its high availability and carbon content, kraft lignin has gained attention as a potential low-cost CF precursor. CFs with promising properties can be made from flexible dry-jet wet spun precursor fibers (PFs) from blends (70:30) of softwood kraft lignin and fully bleached softwood kraft pulp. This study focused on reducing the stabilization time, which is critical in CF manufacturing. The impact of stabilization conditions on chemical structure, yield, and mechanical properties was investigated. It was possible to reduce the oxidative stabilization time of the PFs from about 16 h to less than 2 h, or even omitting the stabilization step, without fusion of fibers. The main reactions involved in the stabilization stage were dehydration and oxidation. The results suggest that the isothermal stabilization at 250 °C override the importance of having a slow heating rate. For CFs with a commercial diameter, stabilization of less than 2 h rendered in tensile modulus 76 GPa and tensile strength 1070 MPa. Impregnation with ammonium dihydrogen phosphate significantly increased the CF yield, from 31–38 to 46–50 wt %, but at the expense of the mechanical properties.

To meet the demand for carbon-fibre-reinforced composites in lightweight applications, cost-efficient processing and new raw materials are sought for. Cellulose and kraft lignin are each interesting renewables for this purpose due to their high availability. The molecular order of cellulose is an excellent property, as is the high carbon content of lignin. By co-processing cellulose and lignin, the advantages of these macromolecules are synergistic for producing carbon fibre (CF) of commercial grade in high yields. CFs were prepared from precursor fibres (PFs) made from 70:30 blends of softwood kraft lignin (SW-KL) and cellulose by dry-jet wet spinning with the ionic liquid (IL) 1-ethyl-3-methylimidazolium acetate ([EMIm][OAc]) as a solvent. In focus was the impact of the molecular mass of lignin and the type of cellulose source on the CF yield and properties, while membrane-filtrated kraft lignin and cellulose from dissolving kraft pulp and fully bleached paper-grade SW-KP (kraft pulp) served as sources. Under the investigated conditions, the yield increased from around 22% for CF from neat cellulose to about 40% in the presence of lignin, irrespective of the type of SW-KL. The yield increment was also higher relative to the theoretical one for CF made from blends (69%) compared to those made from neat celluloses (48–51%). No difference in the mechanical properties of the produced CF was observed.

Material recycling requires solutions that are technically, as well as economically and ecologically, viable. In this work, the technical feasibility to separate textile blends of viscose and polyester using alkaline hydrolysis is demonstrated. Polyester is depolymerized into the monomer terephthalic acid at high yields, while viscose is recovered in a polymeric form. After the alkaline treatment, the intrinsic viscosity of cellulose is decreased by up to 35%, which means it may not be suitable for conventional fiber-to-fiber recycling; however, it might be attractive in other technologies, such as emerging fiber processes, or as raw material for sugar platforms. Further, we present an upscaled industrial process layout, which is used to pinpoint the areas of the proposed process that require further optimization. The NaOH economy is identified as the key to an economically viable process, and several recommendations are given to decrease the consumption of NaOH. To further enhance the ecological end economic feasibility of the process, an increased hydrolysis rate and integration with a pulp mill are suggested.

The demand for carbon fibers (CFs) based on renewable raw materials as the reinforcing fiber in composites for lightweight applications is growing. Lignin-cellulose precursor fibers (PFs) are a promising alternative, but so far, there is limited knowledge of how to continuously convert these PFs under industrial-like conditions into CFs. Continuous conversion is vital for the industrial production of CFs. In this work, we have compared the continuous conversion of lignin-cellulose PFs (50 wt % softwood kraft lignin and 50 wt % dissolving-grade kraft pulp) with batchwise conversion. The PFs were successfully stabilized and carbonized continuously over a total time of 1.0-1.5 h, comparable to the industrial production of CFs from polyacrylonitrile. CFs derived continuously at 1000 °C with a relative stretch of -10% (fiber contraction) had a conversion yield of 29 wt %, a diameter of 12-15 μm, a Young's modulus of 46-51 GPa, and a tensile strength of 710-920 MPa. In comparison, CFs obtained at 1000 °C via batchwise conversion (12-15 μm diameter) with a relative stretch of 0% and a conversion time of 7 h (due to the low heating and cooling rates) had a higher conversion yield of 34 wt %, a higher Young's modulus (63-67 GPa) but a similar tensile strength (800-920 MPa). This suggests that the Young's modulus can be improved by the optimization of the fiber tension, residence time, and temperature profile during continuous conversion, while a higher tensile strength can be achieved by reducing the fiber diameter as it minimizes the risk of critical defects.

Chemical recycling of textiles holds the potential to yield materials of equal quality and value as products from virgin feedstock. Selective depolymerization of textile polyester (PET) from regenerated cellulose/PET blends, by means of alkaline hydrolysis, renders the monomers of PET while cellulose remains in fiber form. Here, we present the mechanism and reactivity of textile PET during alkaline hydrolysis. Part I of this article series focuses on the cellulose part and a possible industrialization of such a process. The kinetics and reaction mechanism for alkaline hydrolysis of polyester packaging materials or virgin bulk polyester are well described in the scientific literature; however, information on depolymerization of PET from textiles is sparse. We find that the reaction rate of hydrolysis is not affected by disintegrating the fabric to increase its surface area. We ascribe this to the yarn structure, where texturing and a low density assures a high accessibility even without disintegration. The reaction, similar to bulk polyester, is shown to be surface specific and proceeds via endwise peeling. Finally, we show that the reaction product terephthalic acid is pure and obtained in high yields.

The potential for using discarded viscose textiles to produce high-quality viscose fibres is limited by the low molecular weight of the cellulose and its continued reduction in the recycling process. Herein, we present a straightforward approach of reprocessing discarded viscose textiles while achieving high-quality recycled viscose fibres. Discarded viscose textile was defibrated and centrifuged, and the resulting fibres were reprocessed under industrially relevant conditions. The produced viscose dope was fluid and resulted in viscose fibres with properties comparable to fibres made from commercial wood cellulose pulp (titer ~2 dtex; dry elongation ~16%, dry tenacity ~15 cN/tex). To explore the potential for a more environmentally friendly production process, the steeping step was performed twice (double-steeping), thereby producing a more homogeneous viscose dope. Through double-steeping, the consumption of carbon disulfide (CS₂) could be reduced by 30.5%. The double-steeping method shows to be a suitable approach to reprocess discarded viscose textiles while reducing the environmental impact of the viscose process associated with the use of CS₂. Our work demonstrates that discarded viscose textile has the potential to be part of a circular textile value chain.