Carbon fibres (CFs), characterized by a carbon content of 90 wt.% or above, derived from polymeric precursors, have garnered considerable interest since their discovery by Shindo in 1961. Their unique properties have led to widespread applications in sectors such as energy, aerospace, medical, and sports, where lightweight structures with excellent mechanical attributes are essential. Anticipated growth in demand for CFs over the next five years underscores the need for a substantial reduction in manufacturing costs.

Currently, the main precursors for carbon fibre (CF) production are poly(acrylonitrile) (PAN), pitch, and cellulose. However, the substantial costs associated with these raw materials and production methods present significant challenges. Alberta oilsands asphaltene (AOA), the heaviest fraction of Alberta Oilsands Bitumen, stands out as a promising alternative precursor. It is estimated to be one to two orders of magnitude less expensive than PAN, and it possesses favorable attributes such as high carbon content, high aromaticity, and abundant reserves. Despite these economic advantages, the brittleness of AOA limits its processing capabilities, impeding the widespread utilization of CFs derived from AOA.

Polymer blending proves to be an effective method for enhancing the physical and chemical properties of polymer materials. This process enhances the melt spinnability of polymers, resulting in improved manufacturing efficiency and enhanced mechanical performance. The effects of polymer blending on the spinnability of AOA, subsequent post-treatment processes, and the ultimate properties of carbon fibres remain poorly. Investigating the behaviors of AOA with and without polymer additives is crucial, as it can provide meaningful insights for the manufacturing of carbon fibres derived from AOA. The manufacturing process for CFs involves melting precursors and processing them into spun fibres, followed by post-treatment processes like stabilization, carbonization, and graphitization. Stabilization process accounts for the most cost and determine the properties of the final carbon fibre products. Better and more efficient stabilization processes account for better performance of carbon fibres. The conditions to stabilize and carbonize AOA fibres, behaviors, and mechanism of the post-treatment remain unclear.

This research focuses on the potential of AOA as a CF precursor, emphasizing (1) preprocessing AOA feedstocks, (2) modifying AOA using polymer additives, (3) designing a melt spinning process for AOA fibres, and (4) employing conventional thermal treatment for post-treatment including stabilization and carbonization processes. Solvent preprocessing and strategic additive use aim to enhance the viscosity and spinnability of AOA. Polystyrene and poly(styrene-butadiene-styrene) are employed and compared as polymer additives for blending with asphaltene, with the anticipation of enhancing the performance of AOA. Melt spinning is proposed for preparing fibres tailored for various applications. Melt spinning system, including extruder, melt pump, and godets, are designed for processing asphaltene sample. Thermal post-treatment, including stabilization and carbonization processes, were performed for stabilizing and carbonizing AOA fibres with or without polymer additives.