A critical review and meta-analysis of energy demand, carbon footprint, and other environmental impacts from carbon fiber manufacturing

Chen, Hao; Liddell, Heather P.H.; Ogale, Amod A.; Miao, Zoe Chunyu; Ijeoma, Muzan Williams; Carbajales-Dale, Michael

doi:10.1016/j.resconrec.2025.108302

Title: A critical review and meta-analysis of energy demand, carbon footprint, and other environmental impacts from carbon fiber manufacturing

Journal Article · 07 April 2025 · Resources, Conservation and Recycling

DOI: https://doi.org/10.1016/j.resconrec.2025.108302 · OSTI ID:2550693

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Clemson Univ., SC (United States)
Purdue Univ., West Lafayette, IN (United States)

The demand for carbon fibers and carbon fiber-reinforced polymers (CFRPs) is rapidly growing due to their outstanding mechanical properties and potential to enhance sustainability, particularly for lightweighting applications. However, carbon fibers are typically produced from fossil-based feedstocks, involve energy-intensive processes, and have limited options for sustainable end-of-life management or circularity. Despite these challenges, the energy demand and lifecycle environmental implications of their production remain poorly understood. Here, we conduct a critical literature review and meta-analysis of carbon fiber manufacturing, revealing significant variations in reported energy demand, carbon footprint, and lifecycle inventory data. Our analysis makes two novel contributions. First, we identify key underlying factors driving these variations. Second, we highlight that carbon fiber, far from being a homogeneous product, has grades varying substantially in mechanical properties, end-use markets, energy intensity of manufacturing processes, and therefore environmental impacts—an aspect often underrepresented in life cycle assessments. We assert that current data are insufficient for reliably evaluating environmental impacts, posing a risk of misleading decision-making. Addressing this gap requires new lifecycle inventory datasets clearly incorporating carbon fiber heterogeneity and key influencing factors identified in this study. Additionally, we propose actionable recommendations, including a checklist, to advance sustainability in the carbon fiber sector.

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Research Organization:: Clemson Univ., SC (United States)

Sponsoring Organization:: USDOE Office of Science (SC), Basic Energy Sciences (BES)

Grant/Contract Number:: SC0023389

OSTI ID:: 2550693

Journal Information:: Resources, Conservation and Recycling, Journal Name: Resources, Conservation and Recycling Vol. 219; ISSN 0921-3449

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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CED
LCA
cumulative energy demand
environmental sustainability
fiber-reinforced polymer composite
grade of carbon fiber
life cycle assessment

Title: A critical review and meta-analysis of energy demand, carbon footprint, and other environmental impacts from carbon fiber manufacturing

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