TECHNOLOGICAL INSTITUTE OF THE PHILIPPINES

363 P. Casal St. Quiapo, Manila

PRODUCTION OF CARBON BLACK

Submitted by: Casidlac, John Darren E.

Submitted to: Engr. Lina Dela Cruz
 INTRODUCTION

Black grades, regardless of the

production method used. Process-related
variations have already been addressed in the
description of the various methods in use today for
obtaining Carbon Black. Without the use of
photographic image analysis the primary particles
of Carbon Black cannot be seen with the naked
eye. It takes the tremendous magnifying power of
a scanning electron microscope (SEM) to show
that Carbon
Figure 1.1 Carbon Black (Solid)
Black consists of chain-like clusters
composed of spherical particles, the so-called primary particles. The product is not supplied in the
form of isolated primary particles, but as larger, tightly bonded aggregates which form the primary
building blocks. The primary particles vary in size and shape to impart specific application
properties. The primary particle size is mentioned to indicate the application properties of a given
product. The aggregates typically form microscale agglomerates during production, present in the
supplied powders or pellets. Figure 24 depicts an SEM view of a single particle. The formation of
spherical, branched aggregates, where the primary particle can have diameters between 10 and 500
nm, is typical of products that develop from the gaseous phase. As we cannot see and measure
primary particles without involving expensive equipment and time consuming methods this form
of Carbon Black has led to the defi nition of two properties

Scanning electron microscope view of a Carbon Black aggregate consisting of fused

primary particle (magnification: x 120,000) that are of primary significance when it comes to
characterizing Carbon Blacks and defining their suitability for specific applications:

• The specific surface area (m2/g) of Carbon Black is a function of primary particle size.
Looking at geometric proportions, we can determine that smaller Carbon Black primary particles
have a higher specific surface area.
• The structure designates the three-dimensional arrangement of primary particles in the
aggregate. Extensive interlinking or branching characterizes a “high structure”, whereas less
pronounced inter-linking or branching indicates a “low structure”. Electron microscopy combined
with X-ray structural micro-analysis, shows that these primary particles consist of concentrically
arranged, graphite-like crystallites. By partially fusing together, the graphite layers are often
twisted into each other, exhibiting a disordered state. A single primary particle can contain up to
1,500 of such crystallites.

A. Properties
Table 1.1 Properties of Carbon Black

PROPERTIES CARBON BLACK

Chemical formula C

Molar mass 12.011 g/mol

Density 1.8-2.1 g/cm3

Melting point 3727 °C

Boiling point 4830 °C

B. Market Study
 Asia Pacific led the global market followed by Europe and North America. Stringent
environmental regulation may have a negative impact on the North America and Europe market.
However, owing to the high demand in tire manufacturing is expected to support the market. High
economic growth along with rapid industrialization and urbanization in the emerging regions of
Asia Pacific have boosted the regional demand for carbon black. Rising foreign investments and
favorable regulatory policies are also contributing to the market growth.

The region is rapidly transforming into a manufacturing hub, which has increased the
demand for the material over the past few years. Major manufacturers are shifting their
manufacturing facilities to countries like India, China, and Vietnam, as they have lower labor costs
and support from the respective governments. Rising automotive production is also expected to
drive the product demand over the forecast period. Initially, the chemical was exported to
developing countries like China, but with a rise in their production capacities, the exports have
reduced.

No existing production plant yet in the Philippines.

Market Overview
 Carbon black market is projected to expand at a CAGR of 5.3% from 2019 to 2026.
 Carbon black is a material formed by the incomplete combustion of petroleum products such as
coal tar.
 Carbon black is produced either by thermal decomposition or partial combustion method, which
includes oil or natural gas as a feedstock.
 It is produced by four different processes, which are furnace black process, channel process, and
acetylene black process, and Lampblack process.

Drivers and Restraints

 There is a rise in demand for carbon black in the tire industry, construction and manufacturing
sectors which use it to provide strength to industrial rubber compounds and other equipment.
 The volatility of raw material prices is anticipated to impede the growth of the global carbon black
market.
 Stringent environmental regulations enacted by the government on the usage of carbon hampers
the growth of the market.
 Nowadays silica as a reinforcing additive in tire applications is becoming popular. This is
anticipated to substitute the usage of carbon which is another significant restraint for the market.
 An increase in the investments in the tire industry coupled with the rise in demand for specialty
grade carbon black in p

Market Growth
 Stringent regulations to curb emissions from factories are expected to play a major role in driving
the market growth.
 Emerging countries in Asia Pacific, such as China, Thailand, India, and Indonesia, are projected
to generate the maximum product demand in the coming years.
 Manufacturers in North America and Europe regions are forced to shift their operations to Asian
countries owing to low cost in emerging countries.
 However, recovery in the automotive industry in countries, such as Germany and France, is
anticipated to boost market growth in Europe over the forecast period.

Market Segmentation
 Based on the grade, the global carbon black market can be classified into standard grade and
specialty grade.
 Specialty grade carbon black is widely used in inks, paints, and coatings.
 An increase in demand for specialty grade carbon black is prompting the black carbon
manufacturers to increase their production capacity or divert them to produce specialty grade
carbon black rather than produce standard grade carbon black.
 By applications, the global carbon black market can be classified into tire rubber, non-tire rubber,
plastics, inks, paints & coatings and others.
 The transportation industry is anticipated to remain the largest segment during the forecast period
due to an increase in demand for tire applications.
 On the other hand, carbon black is widely used in plastics manufacturing, newspapers printing inks
and paints & coatings. Among these, plastics and paints & coatings are commonly utilized in the
construction end-use industry.
 Cabot Corporation to acquire Tech Blend and expand its business footprint agreed to buy Tech
Blend, a Canadian black masterbatches manufacturer. The acquisition extends Cabot’s global
 footprint in carbon black masterbatch and compounds, thus providing a platform to serve global
customers by utilizing Tech Blend’s resources and capabilities.

Geographical Share
 Based on geography, the global carbon black market can be classified into North America, South
America, Europe, Asia Pacific and rest of the world.
 Asia-Pacific occupies the most significant share of carbon black in the world, a majority of the
demand arises from economies such as China and India.
 This is due to the expansion of tire manufacturing facilities and immense growth in the
construction sector.
 Moreover, Asia-Pacific is expected to dominate the overall market during the forecast period, as
the global tire manufacturing companies are shifting their production base to key developing
countries in the region.

Competitive Trends
 Players active in the global carbon black market are highly competitive, with all key players
investing heavily in R&D activities to improve the quality of their products.
 Key players operating in carbon black market are Cabot Corporation, Orion Engineered Carbons
S.A., Phillips Carbon Black Limited, Thai Carbon Black Public Company Limited (Birla Carbon),
Tokai Carbon Co., Ltd., Continental Carbon, and Sid Richardson Carbon & Energy Co. among
others.

Scope of the report

 The report provides an extensive qualitative and quantitative assessment of the present and future
trends in the global carbon black market
 Focus on the various market dynamics that can have an impact on the growth of the market
 Recent industry trends and developments in the carbon black market
 Product mapping for the principal products of all the major market players
 Excel data sheet with thousands of data points of the global carbon black market level 4/5
segmentation
 PDF report with the most relevant analysis cogently put together after exhaustive qualitative
interviews and in-depth market study.
 Key players in the market are profiled, and their recent developments, product portfolio, and other
business strategies are listed

Key Target Audience

 Global Carbon Black Manufacturers
 Suppliers, Dealers, and Distributors of Carbon Black
 Industry Investors/Investment Bankers
 Research Organizations and Academia
 Emerging Companies
 Market Research and Consulting Firms

C. Application

Carbon black is a basic material with a long history, and it has been used as a coloring
agent since the days before Christ. Since carbon black has nano-particles with various functions
such as ultra-violet absorption and conductivity, it is still being applied to new fields such as
electronic equipment and devices. Some applications of carbon black, which is a conventional yet
new material, are shown below.

Rubber Additive

Adding carbon black to products affects materials in a few ways. When used in tires and
other rubber products, it’s primarily a filler, taking the place of more costly binder materials. As a
filler in tires, carbon black also helps extend the life of the tire by conducting heat away from the
tread and belt area. It also acts as a pigment, making rubber materials black.

Coloring Agent for Ink and Paints

Carbon black has higher tinting strength compared to iron black or organic pigments,
and is widely used for newspaper inks, printing inks, India inks, and paints. Carbon black is also
used as black pigment for inkjet ink or toners.
Resin and Film Coloring Agents

Carbon black has high tinting strength and is thermally stable, and therefore it is suitable
for coloring resins and films that are heat-formed. Carbon black is also excellent for absorbing
ultraviolet light, providing both a superb resistance against ultraviolet rays and a coloring effect
when just a small amount is mixed with resins. Carbon black is widely used for general coloring
for resins and films. Resins with carbon black are used in automobile bumpers, wire coverings and
steel pipe linings which require weather resistance in particular.

Electric Conductive Agent

Carbon black particles have the graphite-type crystalline structure, providing an

excellent electric conductivity. Therefore, carbon black is widely used as conductive filler, being
mixed in plastics, elastomer, paints, adhesives, films, and pastes.

Fuel caps and fuel-introducing pipes of automobiles, for example, are required of electric
conductivity for preventing static. Therefore, carbon black is used as an excellent antistatic agent.

Electronic Equipment Related Material

Carbon black also provides stable resistance, and therefore is used as electronic equipment related
material in various display components, magnetic recording materials, and OA rolls.

Furthermore, Mitsubishi Chemical has been developing carbon black with various combined
functions for special applications.

D. Process Description

Carbon black is produced by the reaction of a hydrocarbon fuel such as oil or gas with a
limited supply of combustion air at temperatures of 1320 to 1540°C (2400 to 2800°F). The
unburned carbon is collected as an extremely fine black fluffy particle, 10 to 500 nanometers (nm)
in diameter. The principal uses of carbon black are as a reinforcing agent in rubber compounds
(especially tires) and as a black pigment in printing inks, surface coatings, paper, and plastics. Two
major processes are presently used in the United States to manufacture carbon black, the oil furnace
process and the thermal process. The oil furnace process accounts for about 90 percent of
production, and the thermal, about 10 percent. Two others, the lamp process for production of
lamp black and the cracking of acetylene to produce acetylene black, are each used at 1 plant in
the U. S. However, these are small-volume specialty black operations that constitute less than 1
percent of total production in this country. The gas furnace process is being phased out, and the
last channel black plant in the U. S. was closed in 1976.

Oil Furnace Process

In the oil furnace process (Figure 6.1-1 and Table 6.1-1), an aromatic liquid hydrocarbon
feedstock is heated and injected continuously into the combustion zone of a natural gas-fired
furnace, where it is decomposed to form carbon black. Primary quench water cools the gases to
500°C (1000°F) to stop the cracking. The exhaust gases entraining the carbon particles are further
cooled to about 230°C (450°F) by passage through heat exchangers and direct water sprays. The
black is then separated from the gas stream, usually by a fabric filter. A cyclone for primary
collection and particle agglomeration may precede the filter. A single collection system often
serves several manifolded furnaces. The recovered carbon black is finished to a marketable product
by pulverizing and wet pelletizing to increase bulk density. Water from the wet pelletizer is driven
off in a gas-fired rotary dryer. Oil or process gas can be used. From 35 to 70 percent of the dryer
combustion gas is charged directly to the interior of the dryer, and the remainder acts as an indirect
heat source for the dryer. The dried pellets are then conveyed to bulk storage. Process yields range
from 35 to 65 percent, depending on the feed composition and the grade of black produced.
Furnace designs and operating conditions determine the particle size and the other physical and
chemical properties of the black. Generally, yields are highest for large particle blacks and lowest
for small particle blacks.
Figure 2.1 Production of Carbon Black by Oil Furnace Process
Related Literature

 R. W. Serth and T. W. Hughes, Source Assessment: Carbon Black Manufacture, EPA-

600/2-77-107k, U. S. Environmental Protection Agency, Cincinnati, OH, October 1977.
 Air Pollutant Emission Factors, APTD-0923, U. S. Environmental Protection Agency,
Research Triangle Park, NC, April 1970.
 I. Drogin, "Carbon Black", Journal of the Air Pollution Control Association, 18:216-228,
April 1968.
 Engineering And Cost Study Of Air Pollution Control For The Petrochemical Industry,
Vol. 1: Carbon Black Manufacture By The Furnace Process, EPA-450/3-73-006a, U. S.
Environmental Protection Agency, Research Triangle Park, NC, June 1974.
 K. C. Hustvedt and L. B. Evans, Standards Support And Emission Impact Statement: An
Investigation Of The Best Systems Of Emission Reduction For Furnace Process Carbon
Black Plants In The Carbon Black Industry (Draft), U. S. Environmental Protection
Agency, Research Triangle Park, NC, April 1976.
 Source Testing Of A Waste Heat Boiler, EPA-75-CBK-3, U. S. Environmental Protection
Agency, Research Triangle Park, NC, January 1975.
 R. W. Gerstle and J. R. Richards, Industrial Process Profiles For Environmental Use,
Chapter 4: Carbon Black Industry, EPA-600-2-77-023d, U. S. Environmental Protection
Agency, Cincinnati, OH, February 1977.
 G. D. Rawlings and T. W. Hughes, "Emission Inventory Data For Acrylonitrile, Phthalic
Anhydride, Carbon Black, Synthetic Ammonia, And Ammonium Nitrate", Proceedings Of
APCA Specialty Conference On Emission Factors And Inventories, Anaheim, CA,
November 13-16, 1978.