Making Carbon Black

Presented by
Sid Richardson Carbon Co.

Graphics by Fred Hendrickson

 Carbon Black Process
Boiler
Utilities & Energy
incinerator
Conservation

bag filter vent

secondary filter
(intermittent)
reactor vent
surge tank
(intermittent) grinder
primary bag filter pelletizer

air

dryer
gas
off-spec tank

dryer exhaust tail gas combustor

feedstock secondary quench water bag filter
quench inline waste heat
water boiler

Reactor Section/Carbon Collection & Pelletizing & Storage &

Black Formation Conveying Drying Handling
 Carbon Black Process
Boiler

incinerator

bag filter vent

secondary filter
(intermittent)
reactor vent
surge tank
(intermittent) grinder
primary bag filter pelletizer

air

dryer
gas
off-spec tank

dryer exhaust tail gas combustor

feedstock secondary quench water bag filter
quench inline waste heat
water 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)
 Preheated Reactor
Air

Feedstock
Oil

Natural
Gas Refractory
Reaction Time = 0.3 to 1.0 sec
1650 °C
(3000 °F)

Alkali
Metal 915 m/sec
Quench
Additive (3000 ft/sec)
Water
 Typical Tread Reactor
Air Line

Oil Sprays
Combustion Quench
Section Water
Natural Gas
Typical Tread Reactor
Process Air Preheater To Oil Preheater
& Smoke Header
-to preheat the incoming air

Preheated
Air
650 °C (1200 °F)-
800 °C (1500 °F)

Carbon Black Stream

Process Air
Blower
 Process Oil Preheater
Carbon Black Stream

Hot
Carbon Black
Feedstock
Oil
Oil

To Reactor
Oil Lances To
Bag Filter
 Carbon Black Process
Boiler

incinerator

bag filter vent

secondary filter
(intermittent)
reactor vent
surge tank
(intermittent) grinder
primary bag filter pelletizer

air

dryer
gas
off-spec tank

dryer exhaust tail gas combustor

feedstock secondary quench water bag filter
quench inline waste heat
water boiler

Collection & Conveying – separate carbon black from process gas

stream & transport to pelletizing area
 Bag Filter

Carbon Black Stream

 Bag Filter To Dryers &
Tailgas
Incinerator

Carbon Black Stream

To Surge Bin / Pelletizers

Reverse Flow Bag Filter
Bag Filter Hopper
Surge Bin & Powder Pumps

To Pelletizer
Powder Pump
 Surge Bin & Powder Pumps

Carbon Black
& Air
Clean Air

To Pelletizer
Powder Pump
 Carbon Black Process
Boiler

incinerator

bag filter vent

secondary filter
(intermittent)
reactor vent
surge tank
(intermittent) grinder
primary bag filter pelletizer

air

dryer
gas
off-spec tank

dryer exhaust tail gas combustor

feedstock secondary quench water bag filter
quench inline waste heat
water boiler

Pelletizing & Drying – densify the carbon black to meet transportation &
customer requirements
 Pelletizer
Loose Black from
Powder Pump

Water &
Pellet Binder

Pellets
To Dryer
Two Helix Shaft
Pelletizer
Pelletizer
Pelletizer – Pin Shaft
 Dryer

From Bucket Elevator

Pelletizer To
Storage Tanks

Tailgas
Dryer
 Carbon Black Process
Boiler

incinerator

bag filter vent

secondary filter
(intermittent)
reactor vent
surge tank
(intermittent) grinder
primary bag filter pelletizer

air

dryer
gas
off-spec tank

dryer exhaust tail gas combustor

feedstock secondary quench water bag filter
quench inline waste heat
water boiler

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

Hummer Reject
Screener

Loading Spout
and Screen

Sid Richardson Carbon Co.

 Storage & Loading
Magnetic
Separator

Hummer Reject
Screener

Loading Spout
and Screen
Storage Tanks
 Storage & Loading

Super Sacks 50 # Bags

N299
N299
N299
N299
N299
N299
N299
N299
N299
N299
 Carbon Black Process
Boiler

incinerator

bag filter vent

secondary filter
(intermittent)
reactor vent
surge tank
(intermittent) grinder
primary bag filter pelletizer

air

dryer
gas
off-spec tank

dryer exhaust tail gas combustor

feedstock secondary quench water bag filter
quench inline waste heat
water 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

Measured by nitrogen surface area

Small particles  high nitrogen surface area Tread

Large particles  low nitrogen surface area

Carcass
 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 0.55 kw Electricity 5 kg Water
gas

+ + +
 Structure

Higher additive rate  lower OAN

Low structure 
Low OAN  higher production rates

High structure 
High OAN  lower production rates

OAN = Oil Adsorption Number