Production of Carbon Black in Turbulent Spray Flames of Coal Tar Distillates

Helena Rodriguez-Fernandez,Shruthi Dasappa,Kaylin Dones Sabado,Joaquin Camacho

doi:10.3390/app112110001

Helena Rodriguez-Fernandez, Shruthi Dasappa + Show 2 more

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https://doi.org/10.3390/app112110001

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Abstract

Conventional carbon black production occurs by pyrolysis after heavy aromatic feedstock is injected into the post-combustor region of furnace black reactors. The current work examines the conversion of the coal tar distillate in turbulent spray flames to demonstrate a more compact reactor configuration. Coal tar distillates diluted in toluene is atomized and burned in a standardized flame spray synthesis configuration, known as SpraySyn. Flame conditions are characterized by thermocouple, soot pyrometry and image analysis and product particle properties are examined by TEM and Raman spectroscopy. The measured flame temperature corresponds to the range of temperatures used in the furnace black process, but the current synthesis includes oxidizing conditions and faster residence times. The resulting carbon black particles are aggregates with primary particle sizes on the small end of the carbon black size spectrum, according to analysis of TEM images. Carbon black, formed under a range of flame temperatures, show Raman spectra with features resembling typical carbon black materials. Conversion of coal tar distillate to carbon black by direct flame synthesis may be a scalable method to produce high-surface area grades without a conventional pyrolysis reactor stage.

Highlights

Carbon materials are among the earliest examples of man-made materials deliberately produced for a useful purpose
The furnace black process relies on flames to achieve high reactor temperatures, but the conversion of feedstock to carbon black particles occurs in a downstream pyrolysis process, separated from high-temperature oxidizing conditions
The observed range of flame conditions is expected to impact the production of flame-formed carbon black particles

Summary

Introduction

Carbon materials are among the earliest examples of man-made materials deliberately produced for a useful purpose. From those early times to the present day, flames have been exploited as the primary method to convert organic substances to materials such as carbon black [1]. Carbon particles have been produced in a variety of processes, but the furnace black process has been widely adopted as the most efficient and versatile method for industrial scale production [2,3,4]. The furnace black process relies on flames to achieve high reactor temperatures, but the conversion of feedstock to carbon black particles occurs in a downstream pyrolysis process, separated from high-temperature oxidizing conditions. The unique flame environment may result in useful carbon structure and surface properties without a pyrolysis reactor stage, and this may justify the lower particle yield

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