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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
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