Making Carbon Black
Presented by
Sid Richardson Carbon Co.
Graphics by Fred Hendrickson
Carbon Black Process
Utilities & Energy
Conservation
bag filter vent
(intermittent)
Boiler
incinerator
secondary filter
reactor vent
(intermittent)
surge tank
grinder
primary bag filter
pelletizer
air
dryer
gas
off-spec tank
feedstock
quench
water
secondary quench water
dryer exhaust
bag filter
tail gas combustor
inline waste heat
boiler
Reactor Section/Carbon
Black Formation
Collection &
Conveying
Pelletizing &
Drying
Storage &
Handling
Carbon Black Process
Boiler
incinerator
bag filter vent
(intermittent)
reactor vent
(intermittent)
secondary filter
surge tank
grinder
primary bag filter
pelletizer
air
dryer
gas
off-spec tank
feedstock
quench
water
secondary quench water
dryer exhaust
bag filter
tail gas combustor
inline waste heat
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)
Reactor
Preheated
Air
Feedstock
Oil
Natural
Gas
Refractory
Reaction Time = 0.3 to 1.0 sec
1650 °C
(3000 °F)
Alkali
Metal
Additive
915 m/sec
(3000 ft/sec)
Quench
Water
Typical Tread Reactor
Air Line
Combustion
Section
Natural Gas
Oil Sprays
Quench
Water
Typical Tread Reactor
Process Air Preheater
-to preheat the incoming air
To Oil Preheater
& Smoke Header
Preheated
Air
650 °C (1200 °F)800 °C (1500 °F)
Carbon Black Stream
Process Air
Blower
Process Oil Preheater
Carbon Black Stream
Hot
Feedstock
Oil
To Reactor
Oil Lances
Carbon Black
Oil
To
Bag Filter
Carbon Black Process
Boiler
incinerator
bag filter vent
(intermittent)
reactor vent
(intermittent)
secondary filter
surge tank
grinder
primary bag filter
pelletizer
air
dryer
gas
off-spec tank
feedstock
quench
water
secondary quench water
dryer exhaust
bag filter
tail gas combustor
inline waste heat
boiler
Collection & Conveying – separate carbon black from process gas
stream & transport to pelletizing area
Bag Filter
Carbon Black Stream
Bag Filter
Tailgas
Carbon Black Stream
To Surge Bin / Pelletizers
To Dryers &
Incinerator
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
(intermittent)
reactor vent
(intermittent)
secondary filter
surge tank
grinder
primary bag filter
pelletizer
air
dryer
gas
off-spec tank
feedstock
quench
water
secondary quench water
dryer exhaust
bag filter
tail gas combustor
inline waste heat
boiler
Pelletizing & Drying – densify the carbon black to meet transportation &
customer requirements
Loose Black from
Powder Pump
Pelletizer
Water &
Pellet Binder
Pellets
To Dryer
Two Helix Shaft
Pelletizer
Pelletizer
Pelletizer – Pin Shaft
Dryer
From
Pelletizer
Tailgas
Bucket Elevator
To
Storage Tanks
Dryer
Carbon Black Process
Boiler
incinerator
bag filter vent
(intermittent)
reactor vent
(intermittent)
secondary filter
surge tank
grinder
primary bag filter
pelletizer
air
dryer
gas
off-spec tank
feedstock
quench
water
secondary quench water
dryer exhaust
bag filter
tail gas combustor
inline waste heat
boiler
Storage & Handling – Convey carbon black pellets to storage area for
transportation to customer
Storage & Loading
Magnetic
Separator
Hummer
Screener
Loading Spout
and Screen
Sid Richardson Carbon Co.
Reject
Storage & Loading
Magnetic
Separator
Hummer
Screener
Loading Spout
and Screen
Reject
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
(intermittent)
reactor vent
(intermittent)
secondary filter
surge tank
grinder
primary bag filter
pelletizer
air
dryer
gas
off-spec tank
feedstock
quench
water
secondary quench water
dryer exhaust
bag filter
tail gas combustor
inline waste heat
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
=
1.58 L Oil
Requires
0.32 Nm3 Nat
gas
+
0.55 kw Electricity
+
+
5 kg Water
Structure
Higher additive rate  lower OAN
Low structure 
Low OAN  higher production rates
High structure 
High OAN  lower production rates
OAN = Oil Adsorption Number