Abstract: Carbon black is produced from sources of acetylene and at least one gaseous hydrocarbon selected from the group consisting of ethylenically unsaturated hydrocarbons, aromatic unsaturated hydrocarbons, monocyclic unsaturated hydrocarbons and polycyclic unsaturated hydrocarbons and oxygen. A thermal decomposition of acetylene and a partial combustion-reaction of hydrocarbon independently perform at a moment at the initiation of the reaction; and then, performing mixed reactions of all sources for the reactions in the same region in a reaction furnace.

Abstract: High tint residual carbon black is produced in a vortex flow, venturi oil furnace carbon black reactor by charging the liquid feed or make hydrocarbon axially as a solid jet into a swirling mass of hot combustion gases upstream from the venturi and passing the hydrocarbon feed and hot combustion gases under carbon black forming conditions through the venturi section of the carbon black reactor.

Abstract: Carbon black reactors have dual fluid injectors whereby liquid hydrocarbonaceous feedstock atomized by discharging the feedstock through a dual fluid injector with an atomizing fluid. A method for cleaning coke deposits from such dual fluid injectors comprises interrupting the supply of atomizing fluid thereto a cleaning interval effective to remove the coke deposits.

Abstract: Two carbon black reactors in sequence, one being a high-structure carbon black reactor, the other being a low structure carbon black reactor, one feeding into the other, yield low tint residual carbon black.

Abstract: A method and apparatus for producing carbon black in which combustion gas is introduced into a precombustion or combustion zone of a carbon black reactor in a manner to produce a vortex of combustion gases traveling axially through said reactor and a flow of fluid which contains feedstock is introduced into the reactor in a manner to produce another axially moving vortex internal to the combustion gas vortex with both of these vortices passed through a combustion zone to produce carbon black. In embodiments of the invention, method and apparatus for producing a vortex of feedstock, a vortex of cooling air interfaced with axially flowing feedstock, or combined vortices of feedstock and cooling air.

Abstract: An improved carbon black process is disclosed which finds its preferred use in reactors for forming carbon black by the thermal decomposition of liquid hydrocarbons. The carbon black process utilizes a burner which combusts a pre-mixed blend of fluid fuel and oxidant gas and is characterized by a flame holder having a plurality of elongated parallel orifices which produces improved combustion by inducing optimum recirculation between spaced parallel fluid jets of premixed fuel and oxidant gas issuing through the orifices. This abstract is not to be construed in any way to define or limit the invention set forth below.

Abstract: Carbon black having a tint residual of less than about -5 is produced by injecting a feedstock axially into a vortex flow, oil furnace carbon black reactor having a cylindrical precombustion zone and a frustoconical converging zone.

Abstract: Carbon black is produced in a process comprising prequenching with hollow cone prequench having an included angle effective to produce high tint residual carbon black. Iodine number and tint strength number are changed by changing the included angle of the prequench.

Abstract: Smoke containing unagglomerated carbon black is subjected to sonic carbon black agglomeration thereby reducing the filter load and the danger of heat exchanger blockage.

Abstract: In a carbon black process with tangential hot combustion gas introduction the pressure drop across the reactor is reduced by introducing a gas stream radially outwardly in close proximity with the upstream confining reactor wall.

Abstract: In a carbon black manufacturing process in which an off-specification rerun carbon black is mixed with the carbon black flowing from a carbon black reactor to produce a combined carbon black stream, method and apparatus is provided for controlling the carbon black process so as to insure that the combined carbon black stream will meet predetermined specifications. The feed flow to the carbon black reactor is controlled in response to a comparison of a prediction of the actual surface area of the combined carbon black stream with the desired surface area of the combined carbon black stream so as to provide a combined carbon black stream made up of carbon black particles which have a desired surface area.

Abstract: Startup procedure for carbon black plant comprising producing hot combustion gases low in free oxygen, bringing the hot combustion gases into indirect heat exchange relationship with water to produce a high pressure, saturated stream of steam which is reduced in pressure to produce superheated steam, and cooled hot combustion gases, and using the superheated steam stream to warm bag filters to operating temperatures before starting operation of the plant to produce carbon black. In a preferred embodiment, the superheated steam is combined with the cooled combustion gases and the combined stream used to warm the bag filters.

Abstract: Reject material which has been removed from a thermal black process by a screen and impinged on a plate in the bag filter, can be upgraded by removing material which has been reduced in size by being sucked into the bag filter, and adding that material to the product stream. The material of reduced size is removed by a vibrating screen. Some 50 to 60% of the reject material can be upgraded by this process.

Abstract: Combustion gases containing free oxygen and feed hydrocarbon are introduced into a carbon black reactor, with the combustion gases being at a temperature sufficient to pyrolyze the feed hydrocarbon to produce particulate carbon black. The combustion products are cooled by quenching to form a gaseous effluent containing particulate carbon black. The quenched effluent is discharged from the reactor to an indirect heat exchange means for further cooling the effluent. Control means is provided for producing a signal representative of the rate of heat transfer in the indirect heat exchange means. When the heat transfer rate falls below a predetermined level, the control means closes a valve in the feed hydrocarbon input line to terminate flow of the feed hydrocarbon to the reactor. In the absence of feed hydrocarbon, hot combustion gases flowing through the reactor and the indirect heat exchange means contain sufficient free oxygen to burn out carbon black deposits in the indirect heat exchange means.

Abstract: Carbon black is produced in a reactor by introducing a carbonaceous feed material into one end of the reactor. One or more streams of hot gases are introduced in a direction generally tangential to the side wall of the precombustion zone of the reactor and in a plane generally perpendicular to the longitudinal axis of the reactor to supply heat to decompose the feed material to produce carbon black. This operation is continued until the pressure drop across the reactor reaches a preselected higher value. Thereafter, the stream or streams of hot gases are introduced tangentially to the side wall of the precombustion zone but with each stream being in a respective plane at an angle less than 90.degree. to the longitudinal axis of the reactor and in a downstream direction with respect to the longitudinal axis of the reactor so as to reduce the pressure drop to a lower value.

Abstract: Combustion products containing particulate solids such as carbon black are quenched by indirect heat exchange and the build up of solids deposits on the heat exchange surfaces is minimized or deposits on the heat exchange surfaces are removed by providing a fixed bed of fluidizable particulate solids within the indirect heat exchanger and positioning a shell-tube heat exchanger within the bed of solids with the heat exchange fluid being in the shell side and with the gas stream containing entrained solids such as carbon black passing through the tubes which contain particulate solids. Fluidization of the particulate solids by the gas stream containing carbon black, for example, passing through the tubes cleans or keeps the inner peripheries of the tubes clean.

Abstract: In a carbon black manufacturing process a method is provided whereby the off-gas from at least one carbon black manufacturing process is utilized both to lower the temperature of the hot combustion gases and to provide some heat to the hot combustion gases by being burned in the combustion tunnel of a carbon black reactor. A portion of the off-gas is utilized while still holding the total volume of the hot combustion gases substantially constant at a preselected substantially constant temperature to insure a substantially constant quality of carbon black.

Abstract: Stoichiometric combustion conditions are provided at a location remote from reactor walls in a carbon black process and apparatus by injecting radially inwardly hot combustion gases of a complementary composition with respect to the hot combustion gases introduced tangentially into the reactor.

Abstract: There is set forth a process for the production of furnace black comprising spraying an oily carbon black forming material into a stream of hot combustion gases produced by reaction of fuel with reaction air, chilling and recovery of the carbon black by separation from the waste gases during which the reaction air is heated by means of waste gases. The waste gases are burned in a combustion apparatus by means of secondary air in order to heat the reaction air to a temperature between 600.degree. and 1,250.degree. C., preferably between 800.degree. and 1100.degree. C. and the thus heated reaction air is then introduced into the process.

Abstract: A carbon black reactor capable of producing carbon black of varying properties is disclosed comprising a longitudinally extending reactor tunnel having combustion, reaction, and quench zones in contiguous axial alignment. First and second venturi flow constrictions are provided in spaced relationship in the reaction zone of the reactor tunnel to create a pressure profile in the reaction zone. The pressure profile produces carbon blacks having certain physical properties. The second venturi constriction may be provided with means for varying the effective area of the second constriction for altering the pressure profile in the reactor tunnel to vary the properties of the produced carbon black. Further, carbon blacks of varying properties are produced for a given pressure profile by varying the point and direction of feedstock oil injection into the reaction zone.

Abstract: A process and apparatus for recovering carbon black from hot smoke which comprises passing the smoke through a cyclone separation zone following cooling, then through aggregate filter beds and regeneration of filter beds with clean off-gas which is recycled through the carbon black reaction zone as quench.

Abstract: A start-up technique for a carbon black production process, in which carbon black laden effluent smoke from a carbon black furnace is quenched to terminate the reaction and cool said smoke and said smoke is thereafter cooled, at least in part, by indirect heat exchange with water, in which the smoke is initially quenched with a quench fluid to a temperature substantially below a predetermined temperature of introduction into the heat exchange step and the magnitude of the quenching is reduced over an extended period of time until the smoke is being quenched into a temperature substantially equal to the predetermined temperature.

Abstract: This disclosure relates to an improved furnace process for producing carbon blacks by the incomplete combustion of hydrocarbonaceous feedstock wherein the resultant blacks have higher surface areas than the carbon blacks normally prepared from the feedstocks, as a result of which the blacks are particularly suitable for use in imparting conductivity properites to plastic materials and the like. This disclosure also relates to the production of a novel class of furnace blacks having excellent conductivity properites and which are characterized by high surface areas and low pH values.

Abstract: High quality carbon black forming material convertible with high yield into furnace black having a high abrasion resistance in rubber is prepared by dissolving pitch with conventional thinly liquid carbon black feed stock and mechanically separating suspended matter from the mixture obtained.

Abstract: The tail gas generated by the carbon black process can be used as a source of fuel for drying carbon black without adversely affecting the product properties of the end product if the dried carbon black is heat treated using a fuel free of sulfur and nitrogen compounds.

Abstract: Carbon blacks having a carbon content greater than 99%, a mean particle diameter of 250 to 300 A, an electrical resistivity, measured under a pressure of 6.3 bars, of 0.270 to 0.350 ohm.cm and a DBP index of 400 to 500 ml per 100 g of black are disclosed together with a process for their preparation by incomplete combustion of acetylene in air. These blacks may be used especially for the manufacture of electric cells.

Abstract: In an aspiration chamber of a carbon black reactor, the discharge end of a hydrocarbon inlet and the aspiration inlet of a hydrocarbon reaction section are arranged in such a proximate relationship that the hydrocarbon feed entering from said inlet into said reaction section aspirates surrounding hot combustion gases. The aspiration chamber has a wall converging from the end to which the reaction section is attached towards the end to which the hydrocarbon inlet is attached. Inlets for the combustion gases comprising coal are provided for the tangential feed of the combustion gases into the annulus formed between the reaction section and the converging wall of the aspiration chamber. At least one ash outlet for discharging the ash from the chamber is arranged upstream of the discharge end of the hydrocarbon feed means.

Abstract: A carbon black with a tint residual below -6 in a rubber composition causes the hysteresis or heat buildup of such a rubber composition to be significantly lower than that of a rubber composition incorporating a carbon black with a higher tint residual, while the abrasion resistance of such rubber compositions incorporating these different blacks remains essentially unchanged. Tint residual is the difference between the measured tint and the tint calculated from the structure, nitrogen surface area, and CTAB surface area in accordance with a specific formula disclosed.

Abstract: A method and apparatus are provided for producing carbon black wherein in a carbon black reactor a first quench of effluent flowing through a quench zone is effected by contact of the effluent with water. The first quench cools the effluent to a temperature sufficiently low to stop pyrolysis. Downstream of the first quench is a secondary quench in which cooled smoke ahead of the filters is contacted with the effluent for secondary cooling the effluent. After the second cooling the effluent flows to an indirect heat exchanger wherein the effluent is again cooled, by indirect contact with a coolant in the heat exchanger, to a temperature sufficiently low to prevent damage to the filter system.

Abstract: The present invention provides an effective means of increasing the production rate of a carbon black process. A hydrocarbon fuel is burned in an insufficient amount of air to support complete combustion to produce a hot gas mixture which produces a tail-gas containing carbon black by the incomplete combustion of a hydrocarbon feedstock. This tail-gas is quenched, the carbon black is removed, and the tail-gas is dried. One or more of the combustible components are removed from the dried tail-gas and from 33 1/3% to 100% of the fuel is replaced with the combustible components so removed.

Abstract: Deposits in a carbon black reactor are reduced by passing feed oil, quench water and/or liquid fuel to the reactor through a magnetic field prior to introduction into the reactor.

Abstract: In a carbon black manufacturing process in which an off-specification rerun carbon black is mixed with the carbon black flowing from a carbon black reactor to produce a combined carbon black stream, method and apparatus is provided for controlling the carbon black process so as to insure that the combined carbon black stream will meet predetermined specifications. The feed flow to the carbon black reactor is controlled in response to a comparison of a prediction of the actual surface area of the combined carbon black stream with the desired surface area of the combined carbon black stream so as to provide a combined carbon black stream made up of carbon black particles which have a desired surface area.

Abstract: A method and apparatus for producing carbon black under fine-tuned conditions which comprises measuring a property of the black produced in a tangential introduction of hot gases to produce a vortex operation and adjusting introduction of the hot gases and/or the make oil or gas responsive to said property until it has a desired value. In one embodiment, the adjustment is made manually. In another embodiment, it can be made by a computerized operation. The point of introduction of hot gases can be adjusted by providing at least one movable orifice-carrying element in the conduit supplying the hot combustion gases. The discharge end of the make oil or gas supply pipe can also be relocated according to the measured property.

Abstract: An improved carbon black process burner is disclosed which finds its preferred use in reactors for forming carbon black by the thermal decomposition of liquid hydrocarbons. The burner combusts a pre-mixed blend of fluid fuel and oxidant gas and is characterized by a flame holder having a plurality of elongated parallel orifices which produces improved combustion by inducing optimum recirculation between spaced parallel fluid jets of premixed fuel and oxidant gas issuing through the orifices. This abstract is not to be construed in any way to define or limit the invention set forth below.

Abstract: Combustion gases containing free oxygen and feed hydrocarbon are introduced into a carbon black reactor, with the combustion gases being at a temperature sufficient to pyrolyze the feed hydrocarbon to produce particulate carbon black. The combustion products are cooled by quenching to form a gaseous effluent containing particulate carbon black. The quenched effluent is discharged from the reactor to an indirect heat exchange means for further cooling the effluent. Control means is provided for producing a signal representative of the rate of heat transfer in the indirect heat exchange means. When the heat transfer rate falls below a predetermined level, the control means closes a valve in the feed hydrocarbon input line to terminate flow of the feed hydrocarbon to the reactor. In the absence of feed hydrocarbon, hot combustion gases flowing through the reactor and the indirect heat exchange means contain sufficient free oxygen to burn out carbon black deposits in the indirect heat exchange means.

Abstract: A method of producing carbon black including the steps of burning hydrocarbon fuel, introducing a hydrocarbon feedstock into the combustion gases, quenching the carbon black and gases formed, pelletizing the carbon black with water, drying the pellets with a purge gas and injecting a controlled amount of an oxidant gas into the substantially dry pellets to reduce their modulus-producing properties without reducing their abrasive resistance producing properties and the apparatus therefore.

Abstract: The disclosed apparatus is of the type in which feed units feed air and hydrocarbon material into a reaction chamber, where they react to form carbon black. A filter then removes the carbon black. Disclosed is the provision of a mixing chamber between the feed units and the reaction chamber. The mixing chambers pass through a demountable hollow reactor cover through which there is circulated a heat transfer fluid for controlling the temperature of the mixing chamber walls. The mixing chamber can be common to a plurality of feed units or be separate for each feed unit.Also disclosed is a feed unit which has a vortex plate, an output nozzle, and a hydrocarbon spray nozzle, all mounted on a hydrocarbon supply tube which in turn is fixed to a demountable cover of the feed unit. This permits these components to be readily removed with the cover for replacement or service. The feed units can also have their temperature controlled by the heat transfer fluid for the mixing chambers.

Abstract: In a carbon black manufacturing process a method and apparatus is provided whereby the off-gas from at least one carbon black manufacturing process is utilized both to lower the temperature of the hot combustion gases and to provide some heat to the hot combustion gases by being burned in the combustion tunnel of a carbon black reactor. A portion of the off-gas is utilized while still holding the total volume of the hot combustion gases substantially constant at a preselected substantially constant temperature to insure a substantially constant quality of carbon black.

Abstract: In processes for making carbon black from automobile tires containing fiberglass, or the like, a mat of fiberglass strands intertwined with carbon black trapped in the interstices thereof can be produced. The present invention discloses method and apparatus of producing useful fiberglass and carbon black from such mats. Rapid agitation breaks the mat into a cloud of fine fiberglass particles and free carbon black. A low velocity airstream carries the particles to a separation zone wherein the free carbon black is filtered from the airstream as a first useful by-product. The fiberglass particles are then combusted to remove remaining carbon black carried therewith thus forming a second useful by-product.

Abstract: A carbon black reactor includes a housing which has a refractory lining defining an elongate chamber. The chamber is comprised of a plurality of compartments which include a combustion compartment, a reaction compartment and a quench compartment. An inlet means opens into the combustion compartment and is operable for introducing hot combustion gases into the combustion compartment. Another inlet means opens into the chamber and is operable for introducing a feedstock hydrocarbon into the chamber. Quench liquid inlet means opens into the quench compartment and is operable for introducing quench liquid into the quench compartment. The quench inlet means includes a plurality of tubular members extending into the quench compartment, each having spaced apart discharge openings along the length thereof.

Abstract: Carbon black is produced in a reactor by introducing a carbonaceous feed material into one end of the reactor. One or more streams of hot gases are introduced in a direction generally tangential to the side wall of the precombustion zone of the reactor and in a plane generally perpendicular to the longitudinal axis of the reactor to supply heat to decompose the feed material to produce carbon black. This operation is continued until the pressure drop across the reactor reaches a preselected higher value. Thereafter, the stream or streams of hot gases are introduced tangentially to the side wall of the precombustion zone but with each stream being in a respective plane at an angle less than 90.degree. to the longitudinal axis of the reactor and in a downstream direction with respect to the longitudinal axis of the reactor so as to reduce the pressure drop to a lower value.

Abstract: A carbon black process is disclosed wherein at least a portion of the hydrocarbon feed is axially introduced into a longitudinal reactor, a portion of the hot combustion gases is introduced tangentially into said reactor so that it forms a vortex of hot combustion gases around the hydrocarbon feed and a gas is introduced into the reactor in a mainly radial direction. A reactor for carrying out this process is also disclosed.

Abstract: In the usual elongated carbon black furnace which is provided at one end with a combustion gas entry section, usually of diameter larger than the remainder of the reactor, in lieu of the usual entry port or ports providing hot combustion gases with which to decompose the make oil or gas to carbon black, there are provided independent, double-entry port or pipes. At each double entry there is an outer port and an inner port or pipe. Usually, the pipe approaches the enlarged section or precombustion chamber somewhat tangentially and at a substantial right angle to the longitudinal axis of the elongated reactor or furnace. Thus, viewing the furnace end-on, the outer port or entry will spew its fluid near and onto the walls of the precombustion chamber while the inner port or entry will deliver its gases to a point nearer the longitudinal axis.

Abstract: A method is provided for producing a carbon black with a tint residual below -6. The method entails introducing feedstock axially and generating a hot combustion gas vortex in a cylindrical precombustion section of a tubular carbon black reactor, producing a first mixture of feedstock and combustion gases, passing the mixture through an abruptly restricted passage axially connected to the precombustion section, abruptly expanding the first mixture into a frustoconical venturi converging section of the reactor with mixing of this first mixture with an additional flow of combustion gas at the exit of the converging section with the combustion gas entering the converging section in opposite, radial flow thereby forming a second mixture which is admitted into a reaction section of the carbon black reactor.

Abstract: A solution of an alkali metal inorganic salt in water, oil, and an emulsifier are agitated to form an emulsion. The water is removed from the emulsion which is then filtered. The filtrate is useful as an additive for controlling the structure of carbon black produced in the furnace process.

Abstract: A pyrolysis fuel oil (black oil) is contacted with a promoter liquid having a 5 volume percent distillation temperature of at least 250.degree. F. and a 95 volume percent distillation temperature of at least 350.degree. F. and no greater than about 750.degree. F., with the liquid having a characterization factor of at least 9.75 to promote the separation of quinoline insolubles and asphaltenes from the fuel oil. A fraction free of quinoline insolubles and having a reduced content of asphaltenes may be subjected to coking to produce a needle coke, or employed directly for the production of carbon black.

Abstract: In a carbon black reactor having at least one combustion zone opening into a reaction zone, each combustion zone has opening thereinto, in a generally tangential direction, quench fluid inlet means operably connected to a source of quench fluid. The quench fluid is introduced into the combustion zone to control the temperature of the combustion gases to a desired temperature before the combustion gases are introduced into the reaction zone. Control means is provided for controlling the quench fluid input in response to the temperature of the combustion gases.

Abstract: A pyrolysis fuel oil is treated by soaking in the presence of sulfur for a period of time sufficient to react the highly unsaturated compounds present in the oil, followed by heating the soaked fuel oil at a temperature of from 850.degree. F. to 1100.degree. F. and an outlet pressure of from 300 to 600 psig to provide a treated feed having an API gravity of -3.degree. or less. The feed may be employed for the production of needle coke and/or carbon black and/or electrode binder pitch.

Abstract: A process for manufacturing oil furnace carbon black in which all or a portion of the combustion air is swirled just prior to contacting the fuel. The portion of total air which is swirled is adjustable so as to provide a predetermined, controlled Swirl Ratio in order to control the structure of the resulting carbon black.

Abstract: An apparatus for producing carbon black in which an outer housing has mounted therein a tube which defines a converging/diverging venturi through which hot combustion gases and oil flow for decomposition of the oil to carbon black. The tube has an upstream open end at which position there is a baffle having a through opening which has a diameter smaller than the diameter of the open end of the tube, thereby forming a choke at the upstream end of the tube. The apparatus is also provided with means for introducing fuel or fuel gas, air or oxygen-containing gas and feed oil at the proper positions for the manufacture of carbon black.