Affiliated Research Group:
Key Researcher(s):
Dr. Muhammad Siddiquee
Dr. Mamdouh Al-Harthi
Researchers at KFUPM’s Center for Refining and Advanced Chemicals (IRC-RAC) have developed a low-cost and efficient process that converts heavy oil into graphene and carbon fibers, offering a sustainable and economically viable alternative to conventional carbon material production. Traditionally, heavy oil is burned as fuel for bunker ships, electricity generation, and cement manufacturing, contributing to high carbon emissions and environmental degradation. This innovative method benefits in not only converting undesired heavy oil into valuable carbon materials but also enhances energy efficiency to support cleaner energy goals.
This controlled autoxidation process uses air as an oxidant, eliminating the need for solvents while generating lower CO₂ emissions. The result of this is a refined material with an increased softening point, viscosity, and aromaticity, making it an ideal precursor for carbon fibers. Currently, about 95% of global carbon fiber production relies on polyacrylonitrile (PAN), which is an expensive raw material. By utilizing heavy oil (a low-cost feedstock), the developed process reduces the production costs from ~$35/kg (PAN-based) to < $11/kg, making carbon fiber significantly more accessible. This cost reduction will expand its application beyond high-end industries and create new market opportunities for domestic residual petroleum feedstocks estimated at 340,000 barrels per day.
Carbon materials derived from heavy oil have wide-ranging applications, including automotive, aerospace, marine, construction, wind-turbine blades, sporting goods, semiconductors, and energy storage. By pioneering this cost-effective and sustainable carbon fiber production method, KFUPM is paving the way for a more energy-efficient and environmentally responsible industry. The ability to repurpose abundant heavy oil reserves into valuable carbon materials supports industrial sustainability and enhances Saudi Arabia’s strategic vision for chemical innovation and economic diversification.
Through our commitment to sustainable development, this project aligns with the following United Nations Sustainable Development Goals (SDGs):