What Is Carbon Black? - The Cary Company
What is Carbon Black?Fo c u s e d. I n n o v a t i v e. R e s p o n s i v e.
Contents1 Introduction1.1 About Orion Engineered Carbons1.2 What is Carbon Black4472 Manufacturing Process2.1 Raw Materials2.2 Thermal-Oxidative Processes2.2.1 Furnace Black Process2.2.2 Degussa Gas Black Process2.2.3 Lamp Black Process2.2.4 Channel Black Process (historical)2.3 Thermal Decomposition Processes2.3.1 Thermal Black Process2.3.2 Acetylene Black Process2.4 Carbon Black Dispersions, Compounds,Plastic and Rubber Masterbatches101214141819202121223 Properties of Carbon Black3.1 General Physical and Chemical Properties3.2 Definition of Carbon Black3.3 Test Methods, Chemical and Physical Data3.3.1 Determination of Surface Area3.3.2 Determination of Structure3.3.3 Colorimetric Characterization3.3.4 Chemical and Physical Measurements3.3.5 Physical Appearance and Handling Properties3.4 Specifications and Quality Assurance3.5 Characteristic Data of various Production Processes24252728323333343435364 Handling385 Product Safety5.1 Toxicology5.2 Safety-Related Properties4040416 Applications6.1 Rubber Carbon Blacks6.2 Specialty Carbon Blacks424244233 3
1 Introduction1.1 About Orion Engineered CarbonsWho We Are?Orion Engineered Carbons (OEC) is one of the world’sleading suppliers of Carbon Black. We offer standardand high-performance products for coatings, printinginks, polymers, rubber and other applications. Ourhigh-quality Gas Blacks, Furnace Blacks and SpecialtyCarbon Blacks tint, colorize and enhance the performance of plastics, paints and coatings, inks and toners,adhesives and sealants, tires, and manufactured rubbergoods such as automotive belts and hoses.With 1,360 employees worldwide, Orion EngineeredCarbons runs 14 global production sites and 4 AppliedTechnology Centers, focusing on quality supply andcollaborative partnerships with customers. Commonshares of Orion Engineered Carbons are traded on theNew York Stock Exchange under the symbol OEC.Our Vision“We are the premium supplier of Carbon Black.We generate long-term benefits for stakeholders while remaining committed to responsiblebusiness practices with a focus on team culture, reliability and sustainability.”Strategic Elements of our MissionOperational ExcellenceMarket and TechnologyDriven Product PortfolioReliable PartnerKey Figures4Sales 20141.3 billion EuroNumber of Production Sites14Number of Technical Innovation Centers4Employees1,360Active inover 100 countriesProduction Capacitiy p.a.1.4 million tGrow with Customers
Locations1) USA, BorgerOrion Engineered Carbons LLC9440 FM 1559, Hwy 136Borger, TX 79007, USA2) USA, Kingwood (Regional Headquarters)Orion Engineered Carbons LLC4501 Magnolia Cove DriveSuite 106Kingwood, TX 77345, USA3) USA, OrangeOrion Engineered Carbons LLC1513 Echo RoadOrange, TX 77632, USA4) USA, Belpre (Plant)Orion Engineered Carbons LLC11135 State Route 7Belpre, OH 45714-9496, USA4) USA, Belpre (Technical Center)Orion Engineered Carbons LLC2730 Washington Blvd. Suite 2Belpre, OH 45714, USA5) USA, IvanhoeOrion Engineered Carbons LLC7095 Highway 83Franklin, LA 70538, USA6) Brazil, PaulíniaOrion Engineered Carbons Ltda.Av. Antonio Fadin, 1300Paulínia, SP, CEP 13147-030, Brazil7) Brazil, São PauloOrion Engineered Carbons Ltda.R. Maestro Cardin, 1293São Paulo, SP, 01323-001, Brazil8) Luxembourg(Global Corporate Headquarters)Orion Engineered Carbons S.A.6 Route de Trèves2633 Senningerberg, Luxembourg16) South Africa, Port ElizabethOrion Engineered Carbons PTY (LTD)John Tallant Road6000 Port Elizabeth, South Africa9) France, AmbèsOrion Engineered Carbons SASLieu Dit Saint VincentBP 3, 33810 Ambès, France17) Korea, Bupyeong(Plant and Technical Center)Orion Engineered Carbons Co., Ltd.94, Galsan 1-Dong, Bupyeong-guIncheon, 403-081, South Korea10) Germany, Frankfurt (Global Operationaland Administrative Headquarters)Orion Engineered Carbons GmbHHahnstraße 4960528 Frankfurt a.M., Germany18) Korea, YeosuOrion Engineered Carbons Korea Co., Ltd.350, Wollae-dongYeosu-si, Jeollanam-do, 555-260,South Korea11) Germany, Cologne(Plant and Technical Center)Orion Engineered Carbons GmbHHarry-Kloepfer-Straße 150997 Cologne, Germany19) Japan, TokyoOrion Engineered Carbons KKHolland Hills Mori Tower 16F5-11-2, Toranomon, Minato-Ku,Tokyo 105-0001, Japan12) Germany, DortmundDeutsche Gasrußwerke GmbH & Co KGWeidenstraße 70-7244147 Dortmund, Germany20) China, Shanghai(Regional Headquarters)Orion Engineered Carbons Trading(Shanghai) Co., Ltd.Room 3701-3702BM Intercontinental Business Centre100 Yutong Road200070 Shanghai, China13) Sweden, MalmöNorcarb Engineered Carbons ABKusthamnsgatan 1211 24 Malmö, Sweden14) Poland, JasloOrion Engineered Carbons Sp. z o.o.83 3-go Maja Street38-200 Jaslo, Poland15) Italy, RavennaOrion Engineered Carbons S.r.l.Via Baiona 17048123 Ravenna, Italy20) China, Shanghai (Technical Center)Orion Engineered Carbons MaterialTechnology (Shanghai) Co., Ltd.Room 501-503Building 1, Shanghai Juke Biotech ParkNo. 466 Yindu Road, Xuhui District200231 Shanghai, China5
1 IntroductionHistory of Orion Engineered CarbonsJuly 2014July 2014Common shares of Orion EngineeredCarbons are traded on the New York StockExchange under the symbol OECConversion of line at Borger (Texas, USA) toSpecialty Carbon Black production2013Orion ceases production in Sinès (Portugal)to concentrate European production intofewer, more efficient facilitiesOrion completes conversion of lines atMalmö (Sweden) and Belpre (Ohio, USA) toSpecialty Carbon Black production2013Orion installs a new Rubber Carbon Blackproduction line in Yeosu (South Korea)December 20132011 - 2014Orion EngineeredCarbonsOperates asStandaloneBusinessSeptember 2012May 2013Orion begins reorganization and refocusingof R & D and product development to expand its position as a leader in innovationOrion completes rollout of single instanceSAP platform worldwide to improve efficiency and standardize processes2011Evonik aquires full ownership of AlgoraxPort Elizabeth (South Africa) Joint Venture2010Evonik converts rubber lines into mainlySpecialty Carbon Black production atBelpre (Ohio, USA) and Malmö (Sweden)2009Evonik converts rubber line into SpecialtyCarbon Black20072011 - 2014Established asStandaloneBusiness1998 - 2010RepositioningTowardsSpecialty CarbonBlackEvonik buys out Engineered Carbons JointVenture partner in North America2008Evonik installs two oxidation units for Specialty Gas Black at Cologne (Germany)20022000Degussa forms a Joint Venture withEngineered Carbons in the USA, addingthree plants in Texas, USA (Baytown,Borger and Orange).Paulinia plant (greenfield) in Brazil startsoperations1986 - 20021994InternationalExpansionDegussa forms the first Western/ChineseJoint venture in the field of Carbon Blackin Jiaozhou (China)July 2011Separation of Evonik s Carbon Black business into a new standalone business called„Orion Engineered Carbons“Evonik installs new Specialty Gas Black unitat the German Joint Venture2002Degussa acquires plant in Jaslo (Poland)1999Degussa acquires plants in Bupyeong(Korea) and Yeosu (Korea)1997Degussa aquires plant in Sines (Portugal)19881986Plants acquired in Ivanhoe (Louisiana,USA), Aransas Pass (Texas, USA) and Belpre(Ohio, USA)Plants acquired in Ambès (France), Botlek(Netherlands), Malmö (Sweden), Ravenna(Italy) and Port Elizabeth (South Africa)19581938Start of Furnace Black process in Cologne(Germany)Degussa acquires the remaining shares inAugust Wegelin AG. German Joint Venturestarts using the Gas Black process19561932 - 1958German Joint Venture starts using theFurnace Black processHistoricalBackdrop1932Degussa enters the Carbon Black businessthrough the acquisition of a significantshare in August Wegelin AG6December 2013Orion consolidates all German R & D activities in a single facility (Cologne), therebycreating a global center of excellenceAcquisitions1936Degussa forms a Joint Venture with Deutsche Gasrußwerke GmbH & Co. KG (the„German Joint Venture“) with German tireproducersManagementInitiatives /Joint VenturesCapacityExpansions /Conversions
1.2 What is Carbon Black?Carbon Black is a commercial form of solid carbonthat is manufactured in highly controlled processes toproduce specifically engineered aggregates of carbonparticles that vary in particle size, aggregate size, shape,porosity and surface chemistry. Carbon Black typicallycontains more than 95 % pure carbon with minimalquantities of oxygen, hydrogen and nitrogen. In themanufacturing process, Carbon Black particles are formed that range from 10 nm to approximately 500 nmin size. These fuse into chain-like aggregates, whichdefine the structure of individual Carbon Black grades.Carbon Black is used in a diverse group of materials inorder to enhance their physical, electrical and opticalproperties. Its largest volume use is as a reinforcement and performance additive in rubber products.In rubber compounding, natural and synthetic elastomers are blended with Carbon Black, elementalsulfur, processing oils and various organic processingchemicals, and then heated to produce a wide rangeof vulcanized rubber products. In these applications,Carbon Black provides reinforcement and improvesresilience, tear-strength, conductivity and other physical properties. Carbon Black is the most widely usedand cost-effective rubber reinforcing agent (typicallycalled Rubber Carbon Black) in tire components (suchas treads, sidewalls and inner liners), in mechanical rubber goods (“MRG”), including industrial rubber goods,membrane roofing, automotive rubber parts (such assealing systems, hoses and anti-vibration parts) andin general rubber goods (such as hoses, belts, gasketsand seals).Besides rubber reinforcement, Carbon Black is used asblack pigment and as an additive to enhance materialperformance, including conductivity, viscosity, staticcharge control and UV protection. This type of CarbonBlack (typically called Specialty Carbon Black) is used ina variety of applications in the coatings, polymers andprinting industries, as well as in various other specialapplications.In the coatings industry, treated fine particle CarbonBlack is the key to deep jet black paints. The automotive industry requires the highest jetness of black pigments and a bluish undertones.Small particle size Carbon Blacks fulfill these requirements. Coarser Carbon Blacks, which offer a morebrownish undertone, are commonly used for tintingand are indispensable for obtaining a desired grayshade or color hue.In the polymer industry, fine particle Carbon Black isused to obtain a deep jet black color. A major attributeof Carbon Black is its ability to absorb detrimental UVlight and convert it into heat, thereby making polymers, such as polypropylene and polyethylene, moreresistant to degradation by UV radiation from sunlight.Specialty Carbon Black is also used in polymer insulation for wires and cables. Specialty Carbon Black alsoimproves the insulation properties of polystyrene,which is widely used in construction.In the printing industry, Carbon Black is not only usedas pigment but also to achieve the required viscosityfor optimum print quality. Post-treating Carbon Blackpermits effective use of binding agents in ink for optimum system properties. New Specialty Carbon Blacksare being developed on an ongoing basis and contribute to the pace of innovation in non-impact printing.7
1 IntroductionWith a yearly production volume exceeding ten million metric tons, the most important Carbon Blackmanufacturing process is the Furnace Black method.More than 98 % of the world’s annual Carbon Blackproduction is manufactured through this process.Nevertheless, other manufacturing methods are alsoused in the commercial production of Carbon Black,e.g., for fabrication of Gas Blacks, Lamp Blacks, ThermalBlacks and Acetylene Blacks.The variety of Carbon Blacks, its production methodsand possible applications show that “soot” has come along way. Much has been published about the subjectin technical journals, textbooks, reference works andproduct brochures. This brochure will reveal the manyinteresting facets of Carbon Black - a product that isboth simple and sophisticated. Indeed, many of thethings we take for granted in our everyday lives wouldnot be possible without Carbon Black.History of Carbon BlackAncient civilizations in China and Egypt mixed soot into resins,vegetable oils or tar to create colors and inks. Allowing a flame,usually from an oil lamp, to come in contact with a cooledsurface causes soot to accumulate on the cooled surface. Thesoot could then be scraped off and collected as a powder. Thisprocess, referred to as the impingement process, that involvesusing the flame from an oil lamp was a precursor to today sLamp Black process. However it is also the basis of the Channeland Gas Black processes, which utilize gas flames impinging oncool cast iron channels or rotating cooled cylinders.Later on, both the Greeks and the Romans had a predilectionfor black to decorate walls, resulting in a great need for soot(Figure 1). In what has become a standard work of antiquity,“De Architectura,“ Roman master builder Vitruvius describes inpainstaking detail a technical method in which resin is fired ina brick-lined furnace and Carbon Black is precipitated in largequantities in a special chamber (Figure 2).Figure 1:Roman Fresco, Pompeii82a)
AreaApplicationRubberReinforcing filler in tires and mechanical rubber components, conductivityPrinting InksPigmentation, rheology, tintingCoatingsBlack and grey pigmentation, tintingPlasticsBlack and grey pigmentation, tinting, UV protection, conductivity, conductor coatingFibersPigmentationPaperBlack and grey pigmentation, conductivity, decorative and photo-protective papersConstructionCement and concrete pigmentation, conductivityPowerCarbon brushes, electrodes, battery cellsMetal Reduction CompoundsMetal smelting, friction compoundMetal CarbideReduction compound, carbon sourceFireproofingReduction of mineral porosityInsulationGraphite furnaces, polystyrene and PU foamTable 1:Major Carbon BlackapplicationsMarcus Vitruvius Pollio Ten Books on Architecture(Volume VII, Chapter 10)Black PigmentsNow I come to the pigments, which are converted in such a way that they take on the characteristics of colorpigments only when mixed correctly with other materials and when certain (chemical) processes are employed.First, I want to present the black pigment, the use of which is indispensable in construction. The techniquesrequired to produce the correct mixtures must be known so that these mixtures can be prepared by skilledworkers under appropriate conditions.First, a vaulted chamber is built in the form of a (Roman) steam bath, lined carefully on the inside with marblestucco, and smooth. In front of this chamber a small combustion chamber, and with the inlet opening closedexactly far enough so that the flame does not shoot out.Pine resin is now placed in the furnace. During burning, carbon black develops from the resin because of thegreat heat: this carbon black, passes through the outlet openings into the separation chamber, and is precipitated on the rounded sections of the chamber and of the vaulted ceiling. The carbon black is then collected,with the largest amount of it incorporated into gum Arabic in order to produce black ink. The remainder is mixedwith glue by stucco workers, and is used as wall coating.However, when there is no supply on hand, another procedure must be employed if the work is not to bepostponed due to the delay that must be expected. In such a case, pine brushwood and pine chips must be fedinto the fire; when the brushwood and chips have been converted to charcoal and extinguished, they can beground with glue in the mortar. In this way, a black color is derived which is highly esteemed by stucco workers.In addition, a black coloring agent is produced from wine yeast when this yeast is dried, heated in the furnace,and when the charcoal developed is then ground with glue; when applied to the wall, this coloring agent resultsin an unsurpassed, pleasant coloration. Finally, when yeast from finer types of wine is used, it is not only possibleto produce a black pigment, but also the blue color of the indigo can even be imitated.2c)2b)Figure 2:Description of Carbon Black production process in “De Architectura” by Vitruviusa) Medieval manuscriptb) Latin textc) English translation9
2 Manufacturing ProcessIn answering the question “What is Carbon Black?” theimpact of the production method on the properties ofthe end product suggests that we should first focus onthe available methods before describing the variousproperties of the resulting products.That is because the properties are defined at the earliest stage of the manufacturing process, regardless ofwhether the Carbon Black is intended for use in therubber and plastics industry, the printing industry orfor conductivity applications.History of Carbon BlackThe process has essentially remained the same since Vitruviusfirst described it. Centuries later, the invention of the letterpress would create an even greater demand for Carbon Black,as writing inks, having water like consistencies, had to bereplaced with more viscous printing inks (Figure 3). As a result,manufacturing Carbon Black became a trade, with many entrepreneurs setting up shops with a furnace to produce LampBlack. Figure 4 shows a furnace such as those in use during the18th century.Figure 3:Excerpt from CORNUPIAE,a Latin-German dictionary published in 1780Pine resin proved an ideal raw material for Carbon Black used inprinting inks, and Germany’s Black Forest region soon becamethe epicenter of a thriving industry. Special settling chambersmade it possible to conveniently produce large quantities ofCarbon Black (Figure 5).Figure 4:Ancient Lamp Black processas described in Diderot’s“Encyclopédie” (Paris 1770/80)10
The basic raw material for the production of CarbonBlack consists of hydrocarbons that are split into theirconstituent elements, carbon and hydrogen, by eithera thermal or thermal-oxidative (partial combustion)process. Economically, the thermal-oxidative decomposition has become the predominant method, withthe hydrocarbons taking on a double role since theyserve both as a source of heat and of carbon.This in turn generates the heat required to melt andvaporize the wax. The dark area surrounding the burning wick is in fact wax being transformed into vapor.In the inner, luminous zone, there is a deficiency ofoxygen and it is in this region that soot forms, visibleas the thin black trail that floats up from the tip of theflame. It can be collected by bringing the reactinggases into contact with a cooled surface.A burning candle easily demonstrates how this works.The outermost zone of the flame is where some of thehydrocarbons can burn as there is ample supply ofoxygen nearby to feed the combustion process.Every Carbon Black production method is based onthe two fundamental elements of heat and decomposition; how these stages are arranged is what definesthe difference between the production processes.Chemical ProcessManufacturing MethodMain Raw MaterialsThermal-OxidativeDecompositionFurnace Black processDegussa Gas Black processLamp Black processAromatic oils on coal tar basis or mineral oil, natural gasThermal DecompositionThermal Black processAcetylene Black processNatural gas (or mineral oils)AcetyleneCoal tar distillatesAromatic oils on coal tar basis or mineral oilTable 2:Production methodsand raw materialsFigure 5:Processing pine resin to create pitch, tar and Carbon Black11
2 Manufacturing Process2.1 Raw MaterialsThe preferred feedstock for most Carbon Blackproduction processes, especially the Furnace Blackprocess, is heavy oil with a high content of aromatic hydrocarbons. The aromatic form of carbongives the greatest carbon-to-hydrogen ratio, thusmaximizing the available carbon, and is the mostefficient in terms of Carbon Black yields. Theoretically, the greater the aromaticity the more effic
2.2.1 Furnace Black Process 14 2.2.2 Degussa Gas Black Process 18 2.2.3 Lamp Black Process 19 2.2.4 Channel Black Process (historical) 20 2.3 Thermal Decomposition Processes 21 2.3.1 Thermal Black Process 21 2.3.2 Acetylene Black Process 22 2.4 Carbon Black Di
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