Study on the Structural Characteristics of Narrow Fractions of Catalytic Cracking Slurry and the Formation Pathway of Mesophase Pitch

FDO’s wide boiling range and complex composition hinder controlled synthesis of high-performance mesophase pitch. Here, FDO was separated into light, middle, and heavy narrow fractions by vacuum distillation. Multi-scale characterization traced molecular evolution and mesophase development. The light fraction consists of three-ring aromatics with short alkyl side chains and shows the lowest reactivity, yielding limited condensation and poor stacking with isotropic regions and dispersed spheres. The middle fraction contains four-ring aromatics with moderately extended chains, exhibiting enhanced reactivity and undergoing nucleation, growth, coalescence, and disintegration of mesophase spheres. However, insufficient volatiles restrict shear orientation, forming a mosaic texture. The heavy fraction has four-ring aromatics with the longest alkyl chains and the lowest substitution degree, giving the highest reactivity. During thermal cracking, long chains release abundant radicals and volatiles; directional escape generates shear, promoting rapid growth and ordered alignment of aromatic lamellae. At 440 °C for 12 h, this fraction yields high-quality mesophase pitch with small-domain texture, a low softening point (295 °C), and high anisotropic content (98.8%). The pitch shows excellent spinnability, and derived carbon fibers (tensile strength ~1.45 GPa, modulus ~151 GPa) outperform a commercial reference processed under identical conditions. This study reveals molecular-level regulation of mesophase evolution by narrow fraction structures.