Making Carbon Black

Graphics by Fred Hendrickson

Presented by Sid Richardson Carbon Co.

air

gas

feedstock

surge tank

secondary filter

grinder

dryer

off-spec tank

tail gas combustor

primary bag filter

quench water

pelletizer

Carbon Black Process

reactor vent (intermittent)

dryer exhaust bag filter secondary quench water

incinerator

bag filter vent (intermittent)

inline waste heat boiler

Boiler

Reactor Section/Carbon Black Formation

Collection & Conveying

Pelletizing & Drying

Storage & Handling

Utilities & Energy Conservation

air

gas

feedstock

surge tank

secondary filter

grinder

dryer

off-spec tank

tail gas combustor

primary bag filter

quench water

pelletizer

Carbon Black Process

reactor vent (intermittent)

dryer exhaust bag filter secondary quench water

incinerator

bag filter vent (intermittent)

inline waste heat boiler

Boiler

Reactor Section/Carbon Black Formation – where the carbon black is formed

Raw Materials Making carbon black requires six (6) materials:

–Fuel (natural gas or oil) –Oxidizer (air) –Feedstock Oil (no. 6 type oil) –Water –Structure control additive (potassium salt) –Pellet binder (if required)

Quench Water

Reactor

Natural Gas

Alkali Metal

Additive

Preheated Air

Feedstock Oil

Refractory

1650 °C (3000 °F)

915 m/sec (3000 ft/sec)

Reaction Time = 0.3 to 1.0 sec

Air Line

Oil Sprays Combustion Section

Natural Gas

Quench Water

Typical Tread Reactor

Typical Tread Reactor

Preheated Air

650 °C (1200 °F)- 800 °C (1500 °F)

Process Air Blower

To Oil Preheater & Smoke Header

Carbon Black Stream

Process Air Preheater -to preheat the incoming air

Carbon Black Oil

Hot Feedstock

Oil

To Reactor Oil Lances

Process Oil Preheater

To Bag Filter

Carbon Black Stream

air

gas

feedstock

surge tank

secondary filter

grinder

dryer

off-spec tank

tail gas combustor

primary bag filter

quench water

pelletizer

Carbon Black Process

reactor vent (intermittent)

dryer exhaust bag filter secondary quench water

incinerator

bag filter vent (intermittent)

inline waste heat boiler

Boiler

Collection & Conveying – separate carbon black from process gas stream & transport to pelletizing area

Bag Filter

Carbon Black Stream

Bag Filter Tailgas

To Dryers & Incinerator

Carbon Black Stream

To Surge Bin / Pelletizers

Reverse Flow Bag Filter

Bag Filter Hopper

Surge Bin & Powder Pumps

To Pelletizer

Powder Pump

To Pelletizer

Surge Bin & Powder Pumps

Carbon Black & Air Clean Air

Powder Pump

air

gas

feedstock

surge tank

secondary filter

grinder

dryer

off-spec tank

tail gas combustor

primary bag filter

quench water

pelletizer

Carbon Black Process

reactor vent (intermittent)

dryer exhaust bag filter secondary quench water

incinerator

bag filter vent (intermittent)

inline waste heat boiler

Boiler

Pelletizing & Drying – densify the carbon black to meet transportation & customer requirements

Pellets To Dryer

Pelletizer Loose Black from

Powder Pump

Water & Pellet Binder

Two Helix Shaft

Pelletizer

Pelletizer

Pelletizer – Pin Shaft

Tailgas

Bucket Elevator To

Storage Tanks

From Pelletizer

Dryer

Dryer

air

gas

feedstock

surge tank

secondary filter

grinder

dryer

off-spec tank

tail gas combustor

primary bag filter

quench water

pelletizer

Carbon Black Process

reactor vent (intermittent)

dryer exhaust bag filter secondary quench water

incinerator

bag filter vent (intermittent)

inline waste heat boiler

Boiler

Storage & Handling – Convey carbon black pellets to storage area for transportation to customer

Storage & Loading

Sid Richardson Carbon Co.

Hummer Screener

Reject

Loading Spout and Screen

Magnetic Separator

Storage & Loading

Hummer Screener

Reject

Loading Spout and Screen

Magnetic Separator

Storage Tanks

Storage & Loading

N299 N299

N299

N299 N299

N299

N299

N299 N299

N299

50 # Bags Super Sacks

air

gas

feedstock

surge tank

secondary filter

grinder

dryer

off-spec tank

tail gas combustor

primary bag filter

quench water

pelletizer

Carbon Black Process

reactor vent (intermittent)

dryer exhaust bag filter secondary quench water

incinerator

bag filter vent (intermittent)

inline waste heat boiler

Boiler

Utilities/Energy Conservation – utilize the waste gases from the process for energy conservation and to produce steam and/or electricity

Tail Gas Boiler

Waste Heat Boiler

Process Control & Economics • Particle size (Nitrogen Surface Area)

– 15 to 450 m2/g – Measure of the total surface area

• Surface Area (Iodine Adsorption) – 15 to 450 mg/g – Quick measure of surface area but affected by

surface chemistry • Structure (OAN)

– 40 to 200 ml/100 g – Carbon black particles fuse together to form

aggregates and agglomerates

Particle Surface Area

Small particles high nitrogen surface area

Large particles low nitrogen surface area

Tread

Carcass

Measured by nitrogen surface area

Particle Size

A function of reaction temperature, reaction time and reaction velocity

•Higher reaction temperature = higher nitrogen surface area = higher fuel usage = higher production costs

•Shorter reaction time = higher nitrogen surface area = lower fuel yield = higher production cost

•Greater reaction velocity = shorter reaction time

To Produce 1 kg Of Carbon Black

= Requires

1.58 L Oil 0.32 Nm3 Nat gas

0.55 kw Electricity

+ + +

5 kg Water

Structure

OAN = Oil Adsorption Number

Low structure

Low OAN higher production rates

High structure

High OAN lower production rates

Higher additive rate lower OAN