CARBON BLACK FROM FEEDSTOCK
[EIRI/EDPR/4580] J.C.: 2797XL
INTRODUCTION
The term C-black refers to finally divided carbonaceous Pigments which are derived from pyrolyrish & hydrocarbon gas and oils. Depending upon method of manufacture carbon black may classified into five principal types-lamp black, channel or impigment carbons, thermal blacks, acetylene black and furnace carbon.
The two properties of Carbon black that are most important in commercial applications are particle size and high surface area. Particle size ranges from 100 to 5000 0A & surface area falls within range from 6 to 1,100 m2/gm. Actual C content will vary 83 to 99%. The arrangement of carbon particles may be described as comprising hexagonal nets of carbon atoms, par crystalline in nature. When viewed with an electron microscope particles appear as rough sphere, although they usually are seen in clusters rather than as individual spheres. The aggregating or clustering behavior of C black is considered to be result from physical and chemical bording effects. The manufacturing of Carbon black requires careful monitoring and control over surface area and particle size and because of wide range of control parameters a wide spectrum of C blacks can be created for varying requirements.
The human eye can distinguish 260 shades of blackness. The blackest carbon particle of the commercially available type will have a diameter of about 1000A, whereas greatest particle will have a diameter of approximately 50000A. The blackness of carbons often is referred to as measure those particles having the smaller diameters and great surface areas exhibiting the highest master.
Carbon black is a black fluffy material hence it creates lot of typical handling problems. The workers in plant should be provided with adequate protection against contamination due to inhalation of fumes of powder. Carbon black refers to powder product deposited by contact of flame on the metallic surface.
C black is of very plocculent nature whereas carbon black differs in structurally that carbon black is mainly crystalline with some ommosphons particles blended in it. It is well known that carbon particles have been the cause of luminosity of flames. Scot is formed in luminous planed and it can be collected even through non- surety flame by passing a cold probe through luminous zone. In same way formation of C black in the channel and furnace processes involves the liberation of C particles form flames although in some processes such as thermal the flame is not directly involved. However in both cases carbon is produced by thermal decomposition of hydrocarbons.
COST ESTIMATION
Plant Capacity 36 MT/Day
Land & Building (10,000 sq.mt.) Rs. 5.05 Cr
Plant & Machinery Rs. 12.00 Cr
Working Capital for 1 Month Rs. 7.01 Cr
Total Capital Investment Rs. 24.75 Cr
Rate of Return 32%
Break Even Point 51%
CONTENTS
INTRODUCTION
CARBON BLACK FEEDSTOCK
PRODUCTION
END USE
MARKETING ARRANGEMENT
TECHNICAL SPECIFICATION OF CARBON BLACK FEEDSTOCK
AVAILABILITY OF RAW MATERIAL
B I S SPECIFICATIONS
FAST EXTRUSION FURNACE (FEF) CARBON BLACK
1. SCOPE:-
2. REQUIREMENTS:-
3. PACKING & MARKING:-
4. SAMPLING:-
TABLE-1: REQUIREMENTS FOR FAST EXTRUSION FURNACE (FEP) CARBON BLACK
IS: 7497-1974 SPECIFICATION FOR HIGH ABRASION FURNACE (HAF) CARBON BLACK
1. SCOPE:-
2. REQUIREMENTS:-
TABLE -1: REQUIREMENTS FOR HAF CARBON BLACK
3 PACKING & MARKING:-
4 SAMPLING:-
IS: 8134-1976 SPECIFICATION FOR INTERMEDIATE SUPER ABRASION FURNACE (ISAF) CARBON BLACK
1. SCOPE:-
2. GRADES:-
3. REQUIREMENTS:-
4. PACKING & MARKING:-
5. SAMPLING:-
TABLE-1: REQUIREMENTS FOR INTERMEDIATE SUPER ABRASION FURNACE (ISAF:) CARBON BLACK
IS: 40-1971 SPECIFICATION FOR CARBON BLACK FOR PAINTS
1. SCOPE:-
2. TERMINOLOGY:-
3. CLASSES & TYPES:-
4. REQUIREMENTS:-
5. BACKING & MARKING:-
TABLE -1: REQUIREMENTS FOR CARBON BLACK FOR PAINTS
6. SAMPLING:-
7. TEST METHODS:-
8. CRITERIA FOR CONFORMITY:-
IS: 7498-1974 METHODS OF SAMPLING AND TEST FOR CARBON BLACK
1. SCOPE:-
2. SAMPLING:-
TABLE -1.: NUMBER OF BAG'S TO BE SAMPLED
3. QUALITY OF REAGENTS:-
4.1. APPARATUS:
5. IODINE ABSORPTION NUMBER:-
6. DIBUTYL PHTHALATE ABSORPTION (DBP):-
7. POUR DENSITY:-
8. SIEVE RESIDUE:-
9. LOSS ON HEATING:-
10. ASH CONTENT:-
11. ACETONE EXTRACT EXTRACT :-
12. STAINING TEST:-
14. SULPHUR CONTENT:-
15. PH VALUE:-
USES AND APPLICATIONS
APPLICATIONS OF MAJOR RUBBER GRADE CARBON BLACKS
EFFECTS OF CARBON BLACK COLLOIDAL CHARACTERISTICS ON RUBBER PROCESSING & PHYSICAL PROPERTIES
TYPES OF CARBON BLACKS
STRUCTURE:-
PRINTING INIKS:
PAINT, LACQUERS, ENAMELS & INDUSTRIAL FINISHES:-
PLASTICS:-
PAPER:-
OTHER APPLICATIONS:-
TYPES OF CARBON BLACKS
PROPERTIES OF CARBON BLACK
SIEVE RESIDUE:
PARTICLE SIZE:
FIGURE: CARBON BLACK PARTICLE SIZE COMPARISON
STRUCTURE:
FIGURE: CARBON BLACK STRUCTURE
SURFACE AREA:
SURFACE CHEMISTRY:
POROSITY:
AGGREGATE SIZE:
AGGREGATE SHAPE:
MARKET OVERVIEW OF CARBON BLACK
CARBON BLACK MARKET TRENDS
INCREASING APPLICATION OF TIRES AND INDUSTRIAL RUBBER PRODUCTS
CHINA TO DOMINATE THE MARKET IN THE ASIA-PACIFIC REGION
CARBON BLACK MARKET LEADERS
PRODUCTION OF CARBON BLACK
EXPORT OF CARBON BLACK
CONSUMPTION OF CARBON BLACK
IMPORT OF CARBON BLACK
MANUFACTURING PROCESS OF CARBON BLACK
MANUFACTURING PROCESS HAS THE FOLLOWING SECTION:-
MANUFACTURING PROCESS IN DETAILS
CLASSIFICATION OF CARBON BLACK MANUFACTURING PROCESSES:
TABLE: KINDS OF CARBON BLACK MANUFACTURING PROCESSES
FURNACE BLACK METHOD:
FIGURE: SCHEMATIC DIAGRAM OF THE INDIVIDUAL PROCESS STEPS IN A CARBON BLACK PRODUCTION UNIT
FIGURE: INTERNAL DIAGRAM FOR THE FURNACE BLACK PROCESS
LAMPBLACK PROCESS:
FIGURE: LAMPBLACK PROCESS
CHANNEL BLACK PROCESS:
FIGURE: CHANNEL BLACK PROCESS OR GAS BLACK PROCESS
THERMAL BLACK PROCESS:
FIGURE: THERMAL BLACK PROCESS
ACETYLENE BLACK PROCESS:
FORMATION MECHANISM:-
A MODEL REACTION MECHANISM OF CARBON FORMATION INVOLVES SEQUENTIALLY:-
HEALTH AND SAFETY ASPECTS
BASIC PROCESS OF CARBON BLACK
FURNACE BLACK PROCESS EQUIPMENT:-
TABLE: TIME- TEMP. CONDITION IN CARBON BLACK REACTORS
REACTORS:
POST RECTOR PROCESSING:
(II) THERMAL BLACK
FLOW DIAGRAM FOR CARBON BLACK MANUFACTURER
III. CHANNEL BLACK:-
FROM NATURAL GAS (CHANNEL PROCESS)
PROCESS:-
IV. ACETYLENE BLACK:-
ADDRESSES OF PLANT & MACHINERY SUPPLIERS
ADDRESSES OF PLANT & MACHINERY SUPPLIERS (IMPORTED)
ADDRESSES OF RAW MATERIALS SUPPLIERS
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)