Abstract: A high temperature heat integration method of making carbon black. A method of making carbon black is described, including reacting a carbon black forming feedstock with hydrogen gas in a plasma reactor to produce effluent gas containing carbon black and unused hydrogen, cooling the effluent gas for further processing, and recycling the unused hydrogen back into the carbon black forming process, where the unused hydrogen gas is pre-heated in a heat exchanger to a temperature up to the reaction temperature in the reactor before being recycled into the carbon black forming process. The heat exchanger for use in such process is also described.

Abstract: Systems and methods of making carbon particles with thermal transfer gas. A method of making carbon particles may comprise heating a thermal transfer gas by Joule heating and contacting the thermal transfer gas with a reactive hydrocarbon feedstock gas to generate the carbon particles and hydrogen gas. A method of making carbon particles may comprise heating a thermal transfer gas with the aid of Joule heating and mixing the thermal transfer gas with a hydrocarbon feedstock gas to generate the carbon particles.

Abstract: A method and apparatus for making carbon black. A plasma gas is flowed into a plasma forming region containing at least one, magnetically isolated, plasma torch containing at least one electrode, and forming a plasma. Collecting the plasma formed in a cooled header and flowing the plasma through at least one reaction region to heat the reaction region, and injecting carbon black forming feedstock into the reaction region, resulting in the formation of at least one grade of carbon black. An apparatus for making carbon black is also described including a plasma forming section containing at least one, magnetically isolated plasma torch containing at least one electrode, in fluid flow communication with at least one carbon black forming reactor section, the plasma section and reactor section separated by a plasma formed collection header.

Abstract: Particles with suitable properties may be generated using systems and methods provided herein. The particles may include carbon particles.

Abstract: A method and apparatus for operating a DC plasma torch. The power supply used is at least two times the average operating voltage used, resulting in a more stable operation of the torch. The torch can include two concentric cylinder electrodes, the electrodes can be graphite, and the plasma forming gas can be hydrogen. The power supply provided also has the capability of igniting the torch at a pulse voltage of at least 20 kilovolts.

Abstract: A method and apparatus for making carbon black. A plasma gas is flowed into a plasma forming region containing at least one, magnetically isolated, plasma torch containing at least one electrode, and forming a plasma. Collecting the plasma formed in a cooled header and flowing the plasma through at least one reaction region to heat the reaction region, and injecting carbon black forming feedstock into the reaction region, resulting in the formation of at least one grade of carbon black. An apparatus for making carbon black is also described including a plasma forming section containing at least one, magnetically isolated plasma torch containing at least one electrode, in fluid flow communication with at least one carbon black forming reactor section, the plasma section and reactor section separated by a plasma formed collection header.

Abstract: A torch stinger apparatus may comprise one or more sets of plasma generating electrodes and at least one hydrocarbon injector contained within the electrodes. The electrodes may be concentric. The at least one hydrocarbon injector may be cooled. A method of making carbon particles using the apparatus is also described.

Abstract: The present disclosure provides, for example, systems and methods for generating carbon particles. Carbon particles may have a total content of polycyclic aromatic hydrocarbons of less than or equal to about 0.5 parts per million, a content of benzo[a]pyrene of less than or equal to about 5 parts per billion, and a water spreading pressure that is less than about 5 mJ/m2. A carbon particle among the carbon particles may comprise less than about 0.3% sulfur by weight or less than or equal to about 0.03% ash by weight.

Abstract: Design advances for improving the performance of a plasma torch. The use of one or more of various advances described herein can improve the efficiency and effectiveness of the torch, the reactor and the manufacturing process. The use of the torch with hydrogen plasma gas, natural gas feedstock, and carbon black production are also described.

Abstract: A method and apparatus for making carbon black having increased surface area, reduced grit and/or reduced extract levels. A plasma gas is flowed into a plasma forming region to form a plasma. The plasma then flows through a throat region which is narrower than the plasma forming section, which is connected to a separate carbon black forming region. This causes the plasma to accelerate and become turbulent prior to the exit point in the throat region. The carbon black forming feedstock is injected into the turbulence created by the throat region at a point above, at or near the exit point, resulting in the formation of a carbon black in the separate carbon black forming region. The throat region and/or injector region can be cooled, e.g., water plasma gas cooled.

Abstract: Secondary heat may be added to a particle production process. The particles may be, for example, carbon particles. Among other things, the secondary heat addition may result in change in surface area of the carbon particle(s), change in structure of the carbon particle(s), reduced wall fouling, reduced energy consumption and/or increased throughput. Apparatus for performing the process is also described.

Abstract: Carbon nanoparticles made in a one step process. A method of making carbon black nanoparticles is described, including adding a hydrocarbon to a heated gas to produce carbon nanoparticles that are less than 1 micron volume equivalent sphere and have an Lc greater than 3.0 nm. Elastomer composites containing such particles are also described.

Abstract: A method of cooling a liner in a plasma chamber. A recycle gas is contacted with or passed through the liner to cool the liner and pre-heat the recycle gas. The pre-heated gas is then recycled through the plasma chamber to become part of the plasma forming process. The method further comprises the liner is graphite, the recycle gas passes through at least one cooling channel present in the liner, at least one of the cooling channels are covered with at least one removable liner/channel cover, carbon deposits are formed from the presence of hydrocarbons in the recycle gas, at least one channel is formed in a spiral cooling channel pattern, at least one channel is formed in a substantially straight cooling channel pattern, and a plenum to aid in the production of an even distribution of cooling gas in the channels.

Abstract: A method and apparatus for making carbon black having increased surface area, reduced grit and/or reduced extract levels. A plasma gas is flowed into a plasma forming region to form a plasma. The plasma then flows through a throat region which is narrower than the plasma forming section, which is connected to a separate carbon black forming region. This causes the plasma to accelerate and become turbulent prior to the exit point in the throat region. The carbon black forming feedstock is injected into the turbulence created by the throat region at a point above, at or near the exit point, resulting in the formation of a carbon black in the separate carbon black forming region. The throat region and/or injector region can be cooled, e.g., water plasma gas cooled.

Abstract: A method and apparatus for making carbon black. A plasma gas is flowed into a plasma forming region containing at least one, magnetically isolated, plasma torch containing at least one electrode, and forming a plasma. Collecting the plasma formed in a cooled header and flowing the plasma through at least one reaction region to heat the reaction region, and injecting carbon black forming feedstock into the reaction region, resulting in the formation of at least one grade of carbon black. An apparatus for making carbon black is also described including a plasma forming section containing at least one, magnetically isolated plasma torch containing at least one electrode, in fluid flow communication with at least one carbon black forming reactor section, the plasma section and reactor section separated by a plasma formed collection header.

Abstract: A torch stinger apparatus may comprise one or more sets of plasma generating electrodes and at least one hydrocarbon injector contained within the electrodes. The electrodes may be concentric. The at least one hydrocarbon injector may be cooled. A method of making carbon particles using the apparatus is also described.

Abstract: Secondary heat may be added to a particle production process. The particles may be, for example, carbon particles. Among other things, the secondary heat addition may result in change in surface area of the carbon particle(s), change in structure of the carbon particle(s), reduced wall fouling, reduced energy consumption and/or increased throughput. Apparatus for performing the process is also described.

Abstract: A method of making carbon black. A method of making carbon black is described including combusting feedstock with plasma in an apparatus having a series of unit operations with individual capacities. The individual capacities of the unit operations are substantially balanced by replacing at least part of the feedstock with a feedstock having a molecular weight heavier than methane. This results, among other things, in increased utilization of the individual capacities of the unit operations and increased overall throughput.

Abstract: A method and apparatus for making carbon black having increased surface area, reduced grit and/or reduced extract levels. A plasma gas is flowed into a plasma forming region to form a plasma. The plasma then flows through a throat region which is narrower than the plasma forming section, which is connected to a separate carbon black forming region. This causes the plasma to accelerate and become turbulent prior to the exit point in the throat region. The carbon black forming feedstock is injected into the turbulence created by the throat region at a point above, at or near the exit point, resulting in the formation of a carbon black in the separate carbon black forming region. The throat region and/or injector region can be cooled, e.g., water plasma gas cooled.

Abstract: A method of making carbon black. A method of making carbon black is described including combusting feedstock with plasma in an apparatus having a series of unit operations with individual capacities. The individual capacities of the unit operations are substantially balanced by replacing at least part of the feedstock with a feedstock having a molecular weight heavier than methane. This results, among other things, in increased utilization of the individual capacities of the unit operations and increased overall throughput.