PROCESSES FOR PRODUCING CARBON BLACKS FROM LOW-YIELD RAW MATERIALS AND PRODUCTS DERIVED THEREFROM USING PLASMA OR ELECTRIC HEATING PROCESSES

Abstract

Methods for manufacturing carbon black from low-yield carbon black feedstocks are described using a process that involves the use of electrical energy to cause the formation of carbon black from one or more carbon black feedstocks. Carbon blacks produced from these carbon black feedstocks are further described. Advantages obtained with the methods are further described.

Description

Title of the invention: METHODS FOR PRODUCING CARBON BLACKS FROM LOW YIELD RAW MATERIALS AND PRODUCTS DERIVED THEREFROM USING PLASMA OR ELECTRICALLY HEATED PROCESSES

[0001] The present invention relates to methods of making carbon black from alternative carbon black-producing raw materials, which in many cases may include gaseous and / or low-yield raw materials. More specifically, the present invention relates to methods of making carbon blacks that utilize plasma or electrically heated processes. The present invention further relates to carbon blacks formed from alternative carbon black-producing raw materials that include gaseous and / or low-yield raw materials.

[0002] Carbon black is used to modify mechanical, electrical and optical properties in compositions. Carbon blacks and other fillers are used as pigments, fillers and / or reinforcing agents for the blending and preparation of compositions used in rubber, plastic, paper or textile applications. The properties of the carbon black or other fillers are important factors in determining the various performance characteristics of these compositions. Elastomeric compositions are primarily used for the manufacture of tires and additional ingredients are often added to impart specific properties to the finished product or its components.Carbon blacks are used to modify functional properties, electrical conductivity, rheology, surface properties, viscosity, appearances and other properties in elastomeric and other types of compositions.

[0003] The traditional and most common process for the industrial production of carbon blacks is the furnace process. In this process, a first raw material that contains liquid carbon, such as settling fats, is injected into a hot gas stream that is combusted or in fuel-lean combustion. Some of the raw materials pyrolyze to produce carbon black and by-products (mainly hydrogen); the rest oxidizes to produce CO, CO2, and H2O. Conventional or traditional raw materials are settling fats, settled oily sludge, grease from co kefaction, a coal tar derivative, or a heavy liquid residue from an ethylene cracking process. These carbon black feedstocks are simultaneously heavy (specific gravity > 1.02), have an H:C atomic ratio of 1.23 or less, are rich in aromatics (US Bureau of Mines Correlation Index (BMCI) > 100), and are liquids at room temperature and pressure (e.g., 25°C at 1 atm). They are all generally derived from fossil fuels.

[0004] Electrically heated carbon black production processes are alternatives to the furnace carbon black production process, as described in U.S. Patent No. 1,536,612. In these processes, electricity is used to provide all or part of the energy needed to cause rapid, high-temperature pyrolysis of a carbon-containing feedstock into carbon black particles and gaseous by-products. This is the reverse of the furnace production process, in which partial combustion of a fuel provides this energy. The flue gases are either produced in the carbon-containing feedstock or mixed directly with it to cause pyrolysis to carbon black. Although the furnace production process dominates commercial carbon black production, an electric process offers one or more potential advantages over the furnace process.

[0005] An electric process may use renewable electricity, instead of burning a fossil fuel, giving the process a significantly lower greenhouse gas footprint compared to the furnace process. Electric processes may have a higher yield of carbon black per unit of raw material consumed, resulting in lower operating costs, compared to the furnace process. Using electrical energy to provide all or part of the energy needed to cause pyrolysis may allow for greater control of the gas-phase chemical environment in which the carbon black is formed. Since the energy need not come entirely from combustion, the chemical environment during particle formation can be made more reducing (as opposed to oxidizing).This provides an additional method of controlling the final surface chemistry of the particles.

[0006] Electrically heated carbon black production processes tend to use natural gas, ethane, or similar raw materials that contain gas-phase carbon for carbon black production, as described, for example, in U.S. Pat. No. 10,100,200. One disadvantage of these gas-phase raw materials is their tendency to produce a very poor quality structure for a given surface area. This structure may be of too poor quality to meet the requirements of ASTM grades for the rubber reinforcement.

[0007] Another disadvantage of electrically heated carbon black production processes is that they use a carrier gas. This is because direct exposure of hot, actively heated surfaces, such as those produced at electrodes, to a carbon-containing feedstock can cause rapid coke formation and serious operability problems. In addition, many electrode materials can be corroded in service by high-temperature hydrocarbon gases.

[0008] The use of a carrier gas, such as hydrogen or argon, solves both of these problems, but introduces another: the volume of the carrier gas must be large relative to that of the raw material. Since high temperatures are required to produce adequate surface areas in an aerosol-based carbon black production process, this means that an ever-increasing amount of gas must be used, relative to that of raw material, as the required surface area of ​​the product increases. Increasing the volume of carrier gas significantly increases the investment costs.

[0009] It would be economically useful and environmentally beneficial to use low-yield gaseous, renewable, recycled, and / or sustainable feedstocks within an existing carbon black production process. These feedstocks would not necessarily be fossil fuel-based. They could be ethylene, which can be produced from ethane cracking or bioethanol. They could also be natural gas, which can be fossil-based or produced from landfills or the decomposition of organic matter. These feedstocks could also be vegetable oil, oils derived from the pyrolysis of recycled tires, plastics, municipal waste, or biomass, or natural gas produced from landfills.

[0010] Unfortunately, these low-yield carbon black raw materials generally provide poor yields, reduced surface areas, and / or poor quality structures in a carbon black production process, compared to traditionally used carbon black raw materials. The performance of these raw materials in an electrically heated carbon black production process may also be so poor that it may not be possible to achieve the structure necessary for most ASTM grades with them. The maximum structure that can be achieved with a given surface area for a raw material helps define the grade that the raw material can provide.

[0011] Thus, there is a need in the sector to propose a solution that allows the use of an electrically heated carbon black production process that can significantly improve the structure of the carbon black produced.

[0012] Thus, there is a need in the industry to provide a solution that allows the use of an electrically heated carbon black production process that can significantly improve the quality of the structure of the produced carbon black.

[0013] Furthermore, there is a need in the industry to provide a solution that allows different amounts of low-yield carbon black forming raw materials to be used in an existing electrically heated carbon black production process, and to produce carbon blacks comparable to those formed from traditional raw materials (e.g., producing carbon blacks with acceptable yields and / or large surface areas, and / or high-quality structures). It is more cost-effective in terms of investment and development resources to use an electrically heated carbon black production process that uses these low-yield raw materials, rather than developing, designing, and manufacturing a new process. SUMMARY OF THE PRESENT INVENTION

[0014] One of the objectives of the present invention is to provide methods for preparing or producing carbon black from raw materials such as low yield carbon black raw materials.

[0015] Another object of the present invention is to provide methods for preparing or producing carbon black from raw materials such as gaseous raw materials.

[0016] Another object of the present invention is to provide methods for preparing or producing carbon black using an electrically heated process, and to significantly increase the quality of the structure of the carbon black produced.

[0017] Another object of the present invention is to provide methods for preparing or producing carbon black using an electrically heated process, and to reduce investment costs, by obtaining a given surface area at a lower reaction temperature for the electrically heated carbon black production process.

[0018] Another object of the present invention is to provide carbon blacks produced from raw materials such as low yield raw materials.

[0019] Another object of the present invention is to provide carbon blacks produced from raw materials such as gaseous raw materials.

[0020] Another object is to provide methods of using carbon black raw materials wherein at least a portion or more of the total amount of raw material is low yield carbon black raw material.

[0021] Another objective is to provide a method for producing carbon blacks from low yield raw materials such that the resulting carbon black has acceptable performance (e.g., good), acceptable surface area (e.g., large), and / or acceptable structure (e.g., high quality).

[0022] In order to achieve these and other advantages, and in accordance with the objectives of the present invention, illustrated by way of example and broadly described herein, the present invention, in part, relates to a method of producing a carbon black. The method comprises the step of electrically heating a carrier gas or a carbon black feedstock, or both, to cause pyrolysis of at least a portion of the carbon black feedstock. The carbon black feedstock comprises at least a first carbon black feedstock and at least one low yield carbon black feedstock.In a process of the present invention, the first carbon black feedstock is first contacted with a heated carrier gas formed by electrically heating a carrier gas to form a reaction stream, and then downstream combining the low yield carbon black feedstock with the present reaction stream to form the carbon black. The method further comprises recovering the carbon black from the reaction stream. In the method, the at least one low yield carbon black feedstock preferably comprises at least 10% by weight of the total feedstock and at most 90% by weight of the total feedstock (based on the total weight).

[0023] Further, the present invention, in part, relates to another method of producing a carbon black. The method comprises the step of electrically heating a carrier gas or a carbon black raw material, or both, to cause pyrolysis of at least a portion of the carbon black raw material. The carbon black raw material comprises at least one first carbon black raw material and at least one low-yield carbon black raw material. In the method of the present invention, the first carbon black raw material and the low-yield carbon black raw material are contacted with a heated carrier gas formed by electrically heating a carrier gas to form a reaction stream and form the carbon black.The at least one first carbon black feedstock and at least one low-yield carbon black feedstock may be in the form of a mixture or may be introduced separately at the same or substantially the same location. The method further comprises recovering carbon black from the reaction stream. In the method, the at least one low-yield carbon black feedstock preferably comprises at least 10% by weight of the total feedstock and at most 90% by weight of the total feedstock (based on the total weight).

[0024] Further, the present invention, in part, relates to carbon blacks in wherein at least 10% by weight of the raw material used to form the carbon black is at least one low yield carbon black raw material and at least 10% by weight of the raw material used to form the carbon black is at least one carbon black raw material.

[0025] The present invention further relates to products and / or articles, such as, but not limited to, elastomeric composites formed from one or more of the carbon blacks of the present invention.

[0026] It should be understood that the foregoing general description and the following detailed description are for exemplary and explanatory purposes only and are intended to better explain the present invention.

[0027] The accompanying drawings, which are incorporated in and form a part of this application, illustrate the various features of the present invention and, together with the description, serve to explain the principles of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] [Fig. 1] is a graph illustrating the H:C (hydrogen atom / carbon atom) atomic ratio for traditional carbon black raw materials, as compared to the low yield raw materials that are, in part, used in the present invention. [[Fig. 2]] is a graph illustrating the specific gravity of traditional carbon black raw materials, as compared to the low yield raw materials that are, in part, used in the present invention. [Fig. 3] is a graph illustrating the BMCI value of traditional carbon black raw materials, as compared to the low yield raw materials that are, in part, used in the present invention. [Fig.4] is a cross-sectional view of an exemplary reactor suitable for preparing the carbon black of the present invention. [Fig.5] is a sectional view of another example of a reactor suitable for preparing the carbon black of the present invention. [[Fig.6]] is a cross-sectional view of another example of a reactor suitable for preparing the carbon black of the present invention. DETAILED DESCRIPTION OF THE PRESENT INVENTION

[0029] The present invention relates to methods for producing carbon blacks that utilize low-yield carbon black feedstocks, as defined and described herein, and that utilize an electrically heated carbon black production process. The present invention further relates to carbon blacks produced from one or more of these methods. With the methods of the present invention, a portion of the entire carbon black feedstock used may be one or more low-yield carbon black feedstocks. With the methods of the present invention, not only can low to high amounts of low-yield carbon black feedstocks be used, but, in addition, the quality of the carbon black produced is not sacrificed. Thus, the methods of the present invention utilize carbon black feedstocks that are more desirable for environmental and / or other reasons, and produce carbon blacks comparable to those produced using traditional carbon black feedstocks used with traditional furnace production processes and / or plasma processes.

[0030] A carbon black production process of the present invention comprises, consists essentially of, consists of, or includes combining at least one first carbon black feedstock with an electrically heated gas stream (or an electrically heated carrier gas stream) to form a reaction stream; downstream combining at least one low yield carbon black feedstock with the present reaction stream to form carbon black, and recovering carbon black from the reaction stream.In the process, preferably, the at least one low yield carbon black feedstock comprises at least 10% by weight of the total feedstock, and may preferably comprise at least 25% by weight of the total feedstock or at least 50% of the total feedstock or at least 60% by weight of the total feedstock, and the first carbon black feedstock comprises at least 10% by weight of the total feedstock.

[0031] Another method of the present invention comprises, consists essentially of, consists of, or includes combining a carbon black feedstock that comprises, consists essentially of, consists of, or includes at least one first carbon black feedstock and at least one low yield carbon black with an electrically heated gas stream (or an electrically heated carrier gas stream) to form a reaction stream to form the carbon black, and recovering the carbon black from the reaction stream. The carbon black feedstock may be introduced as a mixture or several separate carbon black feedstocks may be introduced (e.g., at the same or substantially the same location) and combined with the electrically heated gas stream.In the process, preferably, the at least one low yield carbon black feedstock comprises at least 10% by weight of the total feedstock, and may preferably comprise at least 25% by weight of the total feedstock or at least 50% of the total feedstock, and the first carbon black feedstock comprises at least 10% by weight of the total feedstock.

[0032] For the purposes of the present invention, "a carbon black raw material “low yield” is a carbon black raw material that has at least one of the following properties: 1. a US Bureau of Mines Correlation Index (BMCI) < 100 (which indicates low aromatics content for liquid substances) (such as a BMCI less than 99, less than 95, less than 90, less than 85, less than 80, less than 75, less than 70, such as a BMCI between 50 and 99 or between 60 and 99, or between 70 and 99, or between 50 and 95 or between 50 and 90), and / or 2. a material that contains carbon which is a gas at ambient temperature (e.g. 25°C) and pressure (1 atm), and / or 3. an H:C atomic ratio greater than 1.23 (such as an H:C ratio of 1.24 or more, 1.25 or more, 1.26 or more, 1.27 or more, 1.28 or more, 1.29 or more, 1.30 or more, 1.35 or more, 1.40 or more, 1.45 or more, 1.50 or more, between 1.235 and 1.5, or between 1.235 and 1.45, or between 1.235 and 1.4, or between 1.235 and 1.35, or between 1.235 and 1.3 or between 1.235 and 1.29, or between 1.235 and 1.28, or between 1.235 and 1.27 or between 1.24 and 1.5, or between 1.25 and 1.5 or between 1.26 and 1.5 or between 1.27 and 1.5 or between 1.28 and 1.5 or between 1.29 and 1.5 or between 1.3 and 1.5), and / or 4. a specific gravity of 1.02 or less (such as 1.015 or less, 1.01 or less, 1.00 or less, 1.01 or less, 1.00 or less, 0.99 or less, 0.95 or less, between 0.80 and 1.019, or between 0.80 and 1.015, or between 0.80 and 1.01, or between 0.80 and 1.005, or between 0.80 and 1.00, or between 0.80 and 0.95, or between 0.80 and 0.9, or between 0.80 and 1.015, or between 0.90 and 1.01, or between 0.90 and 1.005, or between 1.005 and 1.015).

[0033] The low-yield carbon black raw material may only have the property of BMCI. The low-yield carbon black raw material may only have the property of H:C atomic ratio. The low-yield carbon black raw material may only have the property of specific gravity. The low-yield carbon black raw material may only have the property of gas.

[0034] The low yield carbon black raw material can have the property of BMCI and the property of H:C atomic ratio.

[0035] The low yield carbon black raw material can have the BMCI property and the specific gravity property.

[0036] The low yield carbon black raw material can have the BMCI property and the gas property.

[0037] The low yield carbon black raw material can have the BMCI property, the H:C atomic ratio property and the specific gravity property.

[0038] The low yield carbon black raw material may have the property of BMCI, the H:C atomic ratio property and the gas property.

[0039] The low yield carbon black raw material can have the BMCI property, the H:C atomic ratio property, the specific gravity property and the gas property.

[0040] The low yield carbon black raw material can have the H:C atomic ratio property and the specific gravity property.

[0041] The low yield carbon black raw material can have the H:C atomic ratio property and the gas property.

[0042] The low yield carbon black raw material can have the BMCI property, the specific gravity property and the gas property.

[0043] The low yield carbon black raw material can have the specific gravity property and the gas property.

[0044] A low-yield carbon black feedstock may be a feedstock derived from what are considered sustainable, biological, and / or recycled sources. For example, the low-yield carbon black feedstock may be or may include ethylene, a gas at room temperature and pressure. Ethylene may be produced from bio-based ethanol, such as from the fermentation of corn or the fermentation of other plants. Natural gas is another example of a low-yield carbon black feedstock.

[0045] The low yield carbon black feedstock, for purposes of the present invention, may be a feedstock that is not derived from fossil fuel-based fuel production or coal cracking, or from cracking to produce olefins. Thus, the low yield carbon black feedstock is a feedstock other than coal tar liquid, petroleum refinery liquid, or ethylene cracker unit residue.

[0046] Low yield carbon black feedstocks may also include, but are not limited to, the following: tire pyrolysis oil, plastic pyrolysis oil, recycled oil, algal oil, plant-derived oil, oil derived from the pyrolysis of municipal solid waste, oil derived from the pyrolysis or decomposition of biomass (animal or plant) or agricultural waste, oil derived from the processing of pulp or paper production by-products, and / or other oil derived primarily from biomaterials, or any combination of the foregoing.Exemplary low-yield feedstocks include, but are not limited to, an oil derived from a vegetable or any other plant, bio-based ethanol, a wax or resin produced by a plant or animal, an oil derived from animal fat, an algal oil, an oil from the pyrolysis of sewage sludge or agricultural waste, a by-product liquid from . from the processing of a biogenic material, a liquid produced by hydrothermal liquefaction of a biomaterial, a raw liquid resin, a liquid resin rosin, a liquid resin pitch, or a liquid resin fatty acid, an oil produced from recycled materials, an oil derived from the pyrolysis of non-specification, discarded, or end-of-life tires, an oil derived from the pyrolysis of discarded or recycled plastic or rubber products, an oil derived from the pyrolysis of municipal solid waste, or an oil derived from the pyrolysis of biomass, or any combination of the foregoing. These liquid feedstocks have an H:C atomic ratio greater than 1.23, or a maximum specific gravity of 1.02, or a BMCI value less than 100. Specific examples of low yield carbon black feedstocks are shown in Table 1 below: Label HIJKL Raw Material Example Tire Pyrolysis Oil s Bolder350 Tire Pyrolysis Crude Oil Delta Energy Soybean Oil Corn Oil Peanut Oil Data Source efgh, ih, i Atomic Ratio H:C 1.32 1.50 1.87 1.87 1.87 Specific Gravity 1.00 0.94 0.93 0.92 0.91 BMCI Value 94 62.5 56 54 50 Sulfur Content (wt%) 1.08 1.03 0 0 0 Flash Point 68 32 >110 321 315 Table 1.

[0047] [Fig. 1] is a graph showing the H:C atomic ratio for traditional high-yield carbon black feedstocks, versus tire pyrolysis oils (TPO), vegetable oils (Veg.Oil), and two gas-phase feedstocks (natural gas and ethylene) (Gas). For the materials traditional feedstocks, the H:C ratio is shown for a collection of approximately 1000 representative coal tar liquids, settling oils, and ECRs used as carbon black feedstocks for the furnace production process, between 2016 and 2021. The range of H:C values ​​can be compared with the three groups of low-yield carbon black feedstocks. It is evident that the traditional feedstocks have a low H:C value < 1.23 (the dotted line in the figure). The low-yield carbon black feedstocks in [Fig.l] all have a H:C value > 1.23.

[0048] [Fig. 2] is a graph that shows examples of specific gravity of traditional high-yield carbon black feedstocks, compared to tire pyrolysis oils (TPO) and vegetable oils (Veg. oil). For traditional feedstocks, the specific gravity is shown for a collection of approximately 1000 representative coal tar liquids, settling oils, and ECRs used as carbon black feedstocks for the furnace production process, between 2016 and 2021. The specific gravity range can be compared with two groups of low-yield carbon black feedstocks. It is evident that traditional feedstocks generally have a specific gravity greater than 1.02 (the dotted line in the figure), while low-yield carbon black feedstocks have a specific gravity equal to or less than 1.02.

[0049] [Fig. 3] is a graph showing examples of BMCI values ​​for high-yield traditional feedstocks, compared to tire pyrolysis oils (TPO) and vegetable oils (Veg. oil). For traditional carbon black feedstocks, the BMCI value is shown for a collection of approximately 1000 representative coal tar liquids, decanter oils, and ECRs used as feedstocks for the furnace production process, between 2016 and 2021. Their BMCI values ​​are compared with two groups of low-yield feedstocks. Nearly all traditional feedstocks have a BMCI value > 110, and all examples shown here have a BMCI value greater than or equal to 100 (the dotted line). Conversely, the TPO and vegetable oil groups have a BMCI value less than 100.

[0050] Other examples of low yield carbon black feedstocks may include, but are not limited to, the following: a renewable feedstock, a bio-based or biological feedstock, and / or another by-product of a refining process, or any combination of the foregoing.

[0051] Other examples of low yield carbon black feedstocks may include, but are not limited to, the following: vegetable oils or other oils derived from plants (such as corn oil and / or corn distillers grain oil).

[0052] Other examples of low yield carbon black feedstocks may include, but are not limited to, the following: bio-based ethanol (from the fermentation of corn or the fermentation of other plants, vegetables, or fruits).

[0053] Other examples of low yield carbon black raw materials may include, but are not limited to, the following: waxes and resins of plant or animal origin, such as lanolin or shellac.

[0054] Other examples of low yield carbon black feedstocks may include, but are not limited to, the following: oils derived from animal fats.

[0055] Other examples of low yield carbon black feedstocks may include, but are not limited to, the following: algal oils.

[0056] Other examples of low yield carbon black feedstocks may include, but are not limited to, the following: oils from the pyrolysis of sewage sludge or agricultural waste.

[0057] Other examples of low yield carbon black feedstocks may include, but are not limited to, the following: liquid by-products from the processing of biogenic materials.

[0058] Other examples of low yield carbon black feedstocks may include, but are not limited to, the following: liquids produced by hydrothermal liquefaction of biomaterials.

[0059] Other examples of low yield carbon black feedstocks may include, but are not limited to, the following: liquid rosin oils, liquid rosins, liquid rosin pitches, or liquid rosin fatty acids (e.g., from papermaking processes).

[0060] Other examples of low yield carbon black feedstocks may include, but are not limited to, the following: renewable feedstocks such as oils produced from recycled materials.

[0061] Other examples of low yield carbon black feedstocks may include, but are not limited to, the following: oils derived from the pyrolysis of off-spec, discarded, or end-of-life tires.

[0062] Other examples of low yield carbon black feedstocks may include, but are not limited to, the following: oils derived from the pyrolysis of discarded or recycled plastics.

[0063] Other examples of low yield carbon black feedstocks may include, but are not limited to, the following: oils derived from the pyrolysis of municipal solid waste.

[0064] Other examples of low yield carbon black feedstocks may include, but are not limited to, the following: oils derived from the pyrolysis of biomass (bio-oils), of animal or vegetable origin, for example.

[0065] As indicated above, in the present invention, a portion (in wt%) of the total raw material used in the processes of the present invention (either in stages, or introduced as a mixture or introduced at the same or substantially the same location in the reactor) is composed of one or more low yield carbon black raw materials, and a portion is not a low yield carbon black raw material.

[0066] For the purposes of the present invention, the expression "substantially at the same location" means that the introduction of the multiple raw materials takes place at the same location (II) or within 5% of II based on the total length of the carbon black reactor.

[0067] Preferably, the amount of low-yield carbon black raw material (in stages or introduced as a mixture or introduced at the same or substantially the same location with one or more other carbon black raw materials) is at least 10 wt%, or at least 15 wt%, or at least 20 wt%, or at least 25 wt%, or at least 30 wt%, or at least 35 wt%, or at least 40 wt%, or at least 45 wt%, or at least 50 wt%, or at least 55 wt%, or at least 60 wt%, or at least 65 wt%, or at least 70 wt%, or at least 75 wt%, or at least 80 wt%, or of at least 85% by weight, or at least 90% by weight, but less than 100% by weight and preferably less than 99% by weight or less than 95% by weight, such as between 10 and 95% by weight, or between 10 and 90% by weight, or between 15 and 90% by weight, or between 20 and 90% by weight,or between 25 and 90% by weight, or between 30 and 90% by weight, or between 35 and 90% by weight, or between 40 and 90% by weight, or between 45 and 90% by weight, or between 50 and 95% by weight, or between 10 and 80% by weight, or between 10 and 70% by weight, or between 10 and 60% by weight, or between 10 and 50%, or between 10 and 40% by weight, or between 10 and 30%, or between 60 and 95% by weight, or between 65 and 95% by weight, or between 70 and 95% by weight, or between 75 and 95%, or between 60 and 95% by weight, or between 60 and 90% by weight, or between 60 and 85% by weight, or between 60 and 80% by weight, or between 60 and 75% by weight, based on the total weight percentage of all raw materials used.

[0068] For the purposes of the present invention, a “first carbon black feedstock” or a “high yield carbon black feedstock” is a feedstock that is not a low yield carbon black feedstock as defined herein. The first carbon black feedstock may be considered or designated as a traditional carbon black feedstock used in furnace carbon black production processes (“traditional” carbon black feedstocks). As further described herein, the first carbon black feedstock may be a feedstock mixture that may contain small amounts of a low-yield carbon black feedstock.

[0069] The first carbon black raw materials are generally derived from the family of settling oils or settled oily sludges, coal tars or coal tar distillate fractions, or residues from ethylene or phenol cracking units. Their characteristics, compared to the production of carbon black using a conventional furnace process, are described in more detail below.

[0070] A first carbon black raw material has the following three properties: 1. a BMCI value of at least 100 (such as at least 101, at least 102, at least 103, at least 104, at least 105, at least 110, at least 115, at least 120, at least 130, at least 140, at least 150, at least 160, at least 170, such as between 100 and 180, between 101 and 180, between 102 and 180, between 103 and 180, between 104 and 180, between 105 and 180, between 110 and 180, between 115 and 180, between 120 and 180, between 130 and 180, between 140 and 180, between 150 and 180, between 160 and 180, between 100 and 175, between 100 and 170, between 100 and 165, between 110 and 175, between 115 and 175, between 120 and 175, between 125 and 170, between 130 and 170), 2. a specific gravity greater than 1.02 (e.g. greater than 1.025, greater than 1.03, greater than 1.035, greater than 1.04, greater than 1.05, such as between 1.021 and 1.3, or between 1.025 and 1.3, or between 1.03 and 1.3, or between 1.05 and 1.3, or between 1.07 and 1.25), 3. an H:C atomic ratio of 1.23 or less (e.g., 1.22 or less, 1.21 or less, 1.2 or less, 1.15 or less, 1.1 or less, 1.05 or less, 1 or less, 0.9 or less, 0.8 or less, such as 1.225 to 0.7, 1.225 to 0.8, 1.225 to 0.9, 1.225 to 1, 1.225 to 1.1, 1.22 to 0.7, 1.21 to 0.7, 1.2 to 0.7). Optionally, the first carbon black raw material may also be a liquid at room temperature and pressure (such as 25°C and 1 atm). Although it is a liquid, the first carbon black raw material may be a pitch or similar material that has an extremely high viscosity and does not need to have a remarkable finish.

[0071] Examples of carbon black raw materials are shown in Table 2 below, and include coal tars, liquids distilled from coal tars, settling oils or settled oily sludges obtained from catalytic cracking, and residual oils from ethylene cracking. As shown in Table 2, these raw materials have an H:C ratio of 1.23 or less, a specific gravity greater than 1.02, and a BMCI value of at least 100.

[0072] Table 2: Label ABCDEFG Example of raw material Ethylene steam cracking unit residue Ethylene steam cracking unit residue Settling oil Settling oil Coal tar distillate Crude coal tar Settling oil Data source abacade Atomic ratio H:C 0.94 0.91 0.94 1.01 0.85 0.72 1.01 Specific gravity 1.07 1.08 1.10 1.11 1.14 1.22 1.10 BMCI value 127 146 132 134 161 179 163 Sulfur content (wt%) 0.2 0.17 1.1 0.95 0.6 0.38 1.36 Item 70 86 130 90 90 flash

[0073] The first carbon black feedstock may also include a fraction derived from the refining or distillation of tire pyrolysis oil. Tire pyrolysis may be performed by any method known to those skilled in the art. Exemplary methods include, but are not limited to, those in US8350105 and US20180320082. Distillation of the resulting oil may also be performed by any method known to those skilled in the art. Exemplary methods include, but are not limited to, those in US9920262 and WO2019236214. The tire pyrolysis oil may be distilled to provide at least one fraction that can be used as a first carbon black feedstock and at least one fraction that is a low-yield carbon black feedstock.In fact, distillation can yield light ends that can be used more economically in other parts of the carbon black production process, such as as fuel for a carbon black dryer, or for a heater to preheat one or both of the first carbon black feedstock and the second carbon black feedstock, as described in US20130039841. Thus, integrating the distillation process with the carbon black reactor can provide economic and environmental benefits over the recycling of carbon black-filled tires.

[0074] Optionally, in the methods of the present invention, the first carbon black raw material, based on the total amount of raw material used (in wt. %), may be used in an amount (in stages or introduced as a mixture or introduced at the same location or substantially at the same location with one or more other carbon black raw materials) of at least 10 wt. %, or at least 15 wt. %, or at least 20 wt. %, or at least 25 wt. %, or at least 30 wt. %, or at least 35 wt. %, or at least 40 wt. %, or at least 45 wt. %, or at least 50 wt. %, or at least 55 wt. %, or at least 60 wt. %, or at least 65 wt. %, or at least 70 wt. by weight, or at least 75% by weight, or at least 80% by weight, or at least 85% by weight, or at least 90% by weight,but less than 100% by weight and preferably less than 99% by weight or less than 95% by weight, such as between 10 and 95% by weight, or between 10 and 90% by weight, or between 15 and 90% by weight, or between 20 and 90% by weight, or between 25 and 90% by weight, or between 30 and 90% by weight, or between 35 and 90% by weight, or between 40 and 90% by weight, or between 45 and 90% by weight, or between 50 and 95% by weight, or between 10 and 80% by weight, or between 10 and 70% by weight, or between 10 and 60% by weight, or between , 10 and 50%, or between 10 and 40% by weight, or between 10 and 30%, or between 60 and 95% by weight, or between 65 and 95% by weight, or between 70 and 95% by weight, or between 75 and 95%, or between 60 and 95% by weight, or between 60 and 90% by weight, or between 60 and 85% by weight, or between 60 and 80% by weight, or between 60 and 75% by weight, based on the total weight percentage of all raw materials used.Other amounts of the first carbon black raw material, based on the total amount of raw material used (in wt.%), may be 49 wt.% or less, 45 wt.% or less, 40 wt.% or less, 35 wt.% or less, 30 wt.% or less, 25 wt.% or less, 20 wt.% or less, 15 wt.% or less, 10 wt.% or less, 9 wt.% or less, 8 wt.% or less, 7 wt.% or less, 6 wt.% or less, such as 5-49 wt.% or 5-45 wt.% or 10-40 wt.% or 10-35 wt.% or 10-30 wt.%).

[0075] The first carbon black feedstock may be a liquid at room temperature and pressure (such as 25°C and 1 atm). The term "Aromatic species rich" means that the feedstock has a high amount of aromatic compounds. For example, a high amount of aromatic compounds is understood to mean when the total weight percentage of aromatics present is at least 20% by weight, or when the BMCI value is at least 100, or both. The first carbon black feedstock may be heated so that the feedstock is in vapor form and thus may become or be practically used as an aromatic species rich vapor.

[0076] With respect to the process steps of the present invention, certain processes of the present invention include combining an electrically heated gas stream (or an electrically heated carrier gas stream) with the first carbon black feedstock and a low yield carbon black feedstock.As explained below and above, the first carbon black raw material and the low-yield carbon black raw material may be introduced or combined with the heated gas stream in stages (e.g., the first carbon black raw material is introduced first, then the low-yield carbon black raw material is introduced downstream, or a mixture of the first carbon black raw material and the low-yield carbon black raw material is introduced or combined with the heated gas stream), or the first carbon black raw material and the low-yield carbon black raw material are introduced or combined with the heated gas stream at the same or nearly the same location in the carbon black reactor).

[0077] In other methods of the present invention, the carbon black raw material or portion thereof is electrically heated so that pyrolysis of the raw material is produced.

[0078] In the methods of the present invention, the electrical heating of a carrier gas and / or the carbon black feedstock may be such that the electrical heating is direct or indirect (e.g., in the case of direct heating, the heating element is in contact with the carrier gas and / or the feedstock).

[0079] To create the electrically heated gas stream, there are at least four methods that can be used for the purposes of the present invention. In any of the methods, electrical energy is used to heat a carrier gas and / or a carbon black feedstock such that pyrolysis of at least a portion of the carbon black feedstock occurs.

[0080] The present invention may be embodied in the form of several variations or embodiments.

[0081] In a first method, an arc may be used to electrically heat a carrier gas, which is then contacted with the carbon black feedstock(s), as described herein. Because the arc creates a plasma, this method is sometimes referred to as a "plasma method."

[0082] In a second method, a heating element, either resistive or inductive, is used to electrically heat the carrier gas, which is then contacted with the carbon black raw material(s), as described herein.

[0083] In a third method, an inductive or microwave plasma is used to heat a carrier gas or the carbon black raw materials themselves, without direct contact between the gas and the electrodes.

[0084] In a fourth method, a plasma arc or heating element is in direct contact with the carbon black raw material(s), and is used to heat the raw material. U.S. Patent No. 8,221,689 and U.S. Patent No. 7,563,525 have further described such methods which may be used in the present invention.

[0085] The methods used to form or create the gaseous stream and / or electrically heated carbon black feedstock and the apparatus(es) / device(s) and conditions / parameters to accomplish this are commercially available and may be adopted or used herein for the methods of the present invention.

[0086] More specifically, and simply by way of examples, an example of the first method (a plasma process with carrier gas), and the second method (an electrically heated process with a carrier gas), are described in more detail.

[0087] The plasma process can be used to produce carbon black by heating a suitable carrier gas stream to high temperatures so that pyrolysis of the carbon black raw material(s) can occur when combined with the electrically heated carrier gas stream (e.g. 3000°C or higher). The heating can be carried out with an electric arc. As soon as the carrier gas stream heated carrier gas stream is formed, one or more carbon black feedstock(s) may be introduced into or combined with this heated carrier gas stream. The hot carrier gas stream contains a substantial portion of the energy required to cause rapid, high-temperature pyrolysis of the feedstock into carbon black and gaseous by-products. Further details of this process, which may be adopted in the methods of the present invention, are contained in U.S. Patent No. 9,574,086.

[0088] An exemplary configuration and reactor for the plasma process 10 is illustrated in [Fig. 4], which illustrates a cross-sectional view of a carbon black reactor 10. A carrier gas, such as hydrogen or argon, is introduced, for example, via a conduit 2, into a plasma generation chamber 6 of diameter 5. The overall flow of materials takes place in direction A. The electrodes 3 generate an electric arc 4 which heats the carrier gas, generally under plasma conditions.

[0089] The heated carrier gas is then combined or mixed with a carbon black feedstock, which, for example, may be introduced through injectors 7 and 8. Injector 7 may be positioned at a location that has a diameter smaller than diameter 5. In [Fig. 4], injector 8 is shown downstream of injector 7 at a bottleneck 9 having the smallest diameter of the carbon black reactor 10. Alternatively, injector 8 may be positioned downstream of injector 7 but in an area that has a diameter larger than that of the bottleneck 9. Injector 7, for example, may introduce or inject a first carbon black feedstock into the reactor and another carbon black feedstock, such as a low-yield carbon black feedstock, may be introduced at injection point 8.The distance between the injectors 7 and 8 must be long enough to allow the first carbon black feedstock injected into the reactor 10 at the injector 7 to be mixed with the carrier gas. In the present invention, as a rule, at least some, if not all, of the first carbon black feedstock may be injected or introduced at least before introducing the low-yield carbon black feedstock into the reactor. Preferably, a majority of the first carbon black feedstock is introduced before introducing any low-yield carbon black feedstock. In order to facilitate this mixing process, the hot carrier gas may be forced into the narrower bottleneck 9 to increase turbulence and allow rapid mixing.Since the first carbon black raw material is usually injected as a liquid, the increased turbulence produced by contraction can also facilitate atomization of the liquid droplets.

[0090] After injecting the first carbon black raw material and the material low yield carbon black feedstock, the combined flow of hot carrier gas and reacting feedstock enters a suitable reaction chamber 14 of diameter 11. The diameter 11 and the diameter 5 may be substantially larger than that of the bottleneck 9. At some location 12 downstream of the final feedstock injection point, the mixture is quenched using a gas or liquid spray 13.

[0091] The bottleneck 9 of [Fig. 4] may be optional and not be used. Optionally, only one injection point may be used (e.g., either injection point 7 or injection point 8), at which the first carbon black feedstock and the low-yield carbon black feedstock are introduced as a mixture. As another option, other injection points than the two injection points for the feedstock, illustrated at 7 and 8, may be used.

[0092] It is possible to replace the plasma heating apparatus of [Fig. 4] in whole or in part with a system 15 composed of an electrically resistive heating wire, or induction heated elements, as illustrated in [Fig. 5], which illustrates a cross-sectional view of another reactor 15. The process and apparatus are similar to those of [Fig. 4], except that the carrier gas is now heated by a means other than a plasma generating arc. [Fig. 5] illustrates an assembly of resistive heating elements 16 (such as rods) positioned in the path of a carrier gas which is introduced through a conduit (not illustrated) in a manner similar to the apparatus of [Fig. 4]. In [Fig.5], the resistive heating elements 16 heat the carrier gas flowing in direction A. After the carrier gas heating step, the process may be identical to that described in connection with [Fig.4].Alternatively or additionally, ceramic heating elements, such as magnesium oxide or yttrium-stabilized zirconia, may be used.

[0093] The elements 16 may be heated by subjecting them to a flow of electric current, or may be heated by induction, such as by subjecting them to microwave, radio frequency, or other suitable electromagnetic radiation. As is known in the art, the electromagnetic energy contained in the microwave radiation causes electrons to move in the rods and heat them. This method allows for a reactor without direct penetration for electrical connections, which may be beneficial in some cases. For example, SiC rods become hot when subjected to microwave radiation. In the present embodiment, there is no need for electrical wires or other conductors to cross in the heating chamber, thereby reducing design complexity.

[0094] The methods of the present invention can be applied to a process at electric heating and a reactor as illustrated in [Fig. 6]. [Fig. 6] illustrates a sectional view of another example of a carbon black reactor 20 which has similar characteristics to the apparatus 10 of [Fig. 4]. Unlike [Fig. 4], the reactor 20 has two constricted diameter bottlenecks 64 and 65 at each end of an intermediate chamber 58. The hot carrier gas from conduit 2 flows to the constricted bottleneck 64. The first carbon black feedstock is supplied by injectors 7 or 8, or by both at the same time, and mixed with the carrier gas.

[0095] In [Fig.6], the length from the carrier gas introduction to the middle of the contraction 64 is indicated as length 60. This length may preferably be between IX (times) and 10X the smallest diameter of the first contraction 64. Adjusting this length may balance the carbon black structure and reduce the cost of the process. Height or diameter 5 is illustrated for the heated gas chamber and this height is greater than height or diameter 64. Height or diameter 64 may be at least 20%, at least 30%, at least 40%, at least 50% less than height or diameter 5.

[0096] After the introduction of the first carbon black raw material, the hot gas stream mixed with the raw material enters a first reaction chamber 58. The chamber serves to provide a residence time so that the pyrolysis reactions that produce carbon black can undergo an induction time and then begin, and, possibly, to produce a population of seed particles for the subsequent development of the structure. The length of this chamber 66 can generally be between IX and 20X the smallest diameter of the first contraction 64.

[0097] The low yield carbon black feedstock may be introduced at the end of the first reaction chamber 58. It may be introduced using an injector or group of injectors 59 positioned within or near a second contraction 65 and / or substantially downstream of the first locations 7 and / or 8. Alternatively, the low yield carbon black feedstock may be introduced with a lance substantially upstream of the contraction 65, but into the chamber 58.

[0098] The distance 66 between the contracted bottlenecks 64 and 65 may be greater than the diameter 64 and may be adjusted to modify or optimize the product properties. The contracted bottlenecks 64 and 65 may have the same or different diameters. Those skilled in the art will know how to adjust these diameters to obtain the desired mixing characteristics for the reaction flow.

[0099] After the introduction of the low-yield carbon black raw material, the mixture flows to a second reaction chamber 61. It is then quenched using a cooling spray of liquid or vapor 62, as is known in the art. The length between the injection point of the low-yield carbon black feedstock 59 and the cooling point 62 is indicated at 67 in [Fig. 6]. This length is defined to provide a residence time that controls certain properties of the product, as is known in the art.

[0100] An alternative configuration introduces the first carbon black feedstock at location 7 and / or location 8, and then introduces the low-yield carbon black feedstock at locations 8 and / or 59 (and / or a location therebetween). These two operations can be performed at the same time if both locations are used. This can provide a beneficial trade-off between structural quality and process efficiency or cost. In all of the foregoing embodiments, at least a portion, preferably the majority of the first carbon black feedstock that is used, for example, or all of the first carbon black feedstock, is introduced before and upstream of the low-yield carbon black feedstock.

[0101] With the present invention, the methods allow the use of a gas phase carbon black feedstock or any other non-traditional low yield carbon black feedstock to produce carbon black structures of a higher quality than can be obtained with conventional methods that may use non-traditional carbon black feedstocks.

[0102] Furthermore, with the present invention, it is possible to reduce the temperature required to produce a given surface, compared to the exclusive use of non-traditional raw materials. This means that a reduced amount of carrier gas is required, and allows for reduced investment costs in the electrically heated process. For example, the temperature can be reduced by 2 to 5% or more.

[0103] The injector 7, for example, may introduce or inject a first carbon black feedstock into the reactor. Alternatively, the first carbon black feedstock may also be introduced into the chamber using an axial conduit or a lance. As another alternative, the first carbon black feedstock may be injected or introduced by more than one method at the same time. The lance or any other injector exposed to the reactor may need to be cooled or protected from excessive heat in the reactor, by methods known in the art.

[0104] In the present invention, optionally, at least all or part of the first carbon black raw material may be injected or introduced before introducing the low yield carbon black feedstock into the reactor. Preferably, the amount of the first carbon black feedstock injected or introduced into the reactor before introducing the low yield carbon black feedstock is greater than the total amount of first carbon black feedstock introduced in subsequent stages. Thus, the majority (>50%) of the first carbon black feedstock used in the reactor is introduced or injected in the first stage (e.g., at location / injector 7 in [Fig.4]).

[0105] The carbon black raw materials may be injected into the heated carrier gas stream through one or more nozzles designed for optimal distribution of the raw material into the gas stream. These nozzles may be single-fluid or dual-fluid. Dual-fluid nozzles may use, for example, steam, air, or nitrogen to atomize the raw material. Single-fluid nozzles may be pressure atomized, or the raw material may be directly injected into the gas stream. In the latter case, atomization occurs by the force of the gas stream.

[0106] The carbon black raw material may be injected by an axial injection lance or a central conduit may be used and / or one or more radial lances may be provided on the circumference of the reactor on a plane perpendicular to the flow direction. A reactor may contain several planes with radial lances in the flow direction. Spray or injection nozzles may be provided on the head of the lances, with the help of which the raw material is mixed into the heated gas flow.

[0107] The first carbon black feedstock may be introduced at one or more locations, or at two locations at the same time, or at three or more locations simultaneously. The division of the injection of the first feedstock, if multiple locations are used, between these locations may be varied to modify the product properties and reduce the cost of the process. The injectors and the reactor chamber(s) (or portions thereof) may be cooled if necessary by methods known in the art.

[0108] In another example of the present invention, the first carbon black feedstock may be a mixture of a high-yield carbon black feedstock that satisfies the BMCI value, specific gravity, and H:C ratio parameters described above and a low-yield carbon black feedstock, provided that the mixture satisfies the BMCI value, specific gravity, and H:C ratio parameters described above for the first carbon black feedstock. The mixture may contain more than 50% by weight of the high-yield carbon black feedstock by mass (e.g., 50.5 to 99.5% by weight of the high-yield carbon black raw material, such as 60 to 99% by weight).

[0109] Similarly, the low-yield carbon black feedstock may optionally be a blend of a high-yield carbon black feedstock and a low-yield carbon black feedstock that does not meet at least one of the BMCI value, H:C ratio, and specific gravity parameters required for the first carbon black feedstock, provided that the blend also does not meet at least one of the BMCI value, H:C ratio, and specific gravity parameters required for the first carbon black feedstock. The low-yield carbon black feedstock may be present in an amount greater than 50% of the total feedstock of this optional blend, by mass (e.g., 50.5 to 99.5% by weight of the low-yield carbon black feedstock, such as 60 to 99% by weight).

[0110] Additionally, optionally, the total amount of first carbon black feedstock introduced into the reactor by the sum of all injection locations may be less than 50 wt% based on the total amount of carbon black feedstock used anywhere in the reactor. The total amount of low yield carbon black feedstock may be greater than 50 wt% based on the total feedstock.

[0111] Optionally, in a method of the present invention, the method comprises the step of introducing at least one first carbon black raw material with the heated gas stream into the carbon black reactor to form a reaction stream. The first carbon black raw material may be one or a combination of two or more different first carbon black raw materials. When multiple types of raw materials are used as the first carbon black raw material, the multiple first carbon black raw materials may be mixed together and injected as a mixed material through one or more locations, or each raw material may be injected separately into the reactor at the same location or different locations.

[0112] Optionally, in a method of the present invention, the method comprises the step of introducing at least one low-yield carbon black feedstock into a reaction stream. The low-yield carbon black feedstock may be one or a combination of two or more different low-yield carbon black feedstocks. When multiple types of feedstocks are used as the low-yield carbon black feedstock, the multiple low-yield carbon black feedstocks may be mixed together and injected as a mixed material through one or more multiple location(s), or each raw material can be injected separately into the reactor at the same location or at different locations.

[0113] Generally, all carbon black feedstocks used in any of the processes of the present invention may be injected into a reactor by a single stream or a plurality of streams using injectors, which penetrate the interior areas of the heated gas stream. An injector can further ensure a high level of mixing and shear of the heated gas stream and the carbon black feedstock(s). This ensures that the feedstock pyrolyzes, and preferably at a rapid rate and / or high yield, to form the carbon black of the present invention.

[0114] The first carbon black feedstock may be introduced at one location in the reactor, or at more than one location in the reactor. In one embodiment of the present invention, the low yield carbon black feedstock may be introduced at one location in the reactor, or at more than one location in the reactor. As indicated, in this method of the present invention, the location(s) in the reactor may be downstream of the location(s) at which the first carbon black feedstock is injected or introduced. The introduction of the low yield carbon black feedstock may be accomplished with one or more injectors (such as a metal conduit(s) located on the reactor wall) that introduce(s) the feedstock into the reactor.The injector may have an injector head or a spray head on the end. The injector on the end may have, for example, one or more orifice(s) (2, 3, 4 or more) around the end (usually several orifices evenly distributed).

[0115] Optionally, the introduction of the low yield carbon black feedstock into the reactor and into the reaction stream may be such that the feedstock is introduced perpendicular to the side flow of the reaction stream into the reactor, as illustrated for example in Figures 4-6. "Perpendicular" can mean plus or minus 15 degrees from an actual perpendicular injection of the feedstock into the reaction stream.

[0116] Optionally, the introduction of the low-yield carbon black feedstock into the reactor may be carried out at a location that has a smaller diameter than the reactor into which the first carbon black feedstock was previously introduced. For example, injector 8 of [Fig. 4] is in a narrower portion of reactor 10 than injector 7. This location may be considered a "choke" in some carbon black reactors. This reduced diameter may be at least 10% smaller, at least 20% smaller or at least 30% lower, or 10 to 40% lower than the diameter of the reactor into which the first carbon black feedstock was previously introduced.

[0117] Optionally, the introduction of the low yield carbon black feedstock into the reactor and into the reaction stream may be carried out at a location which is at a distance from that at which the first carbon black feedstock is introduced or injected into the reactor, and this distance may be equal to at least 1 or at least 2 times the smallest diameter, such as diameter 9 or 64, of the initial chamber 6 of the reactor (or is equal to at least 2 times the diameter of the reactor into which the first carbon black feedstock was introduced or injected).This distance may be at least 2.25, at least 2.5, at least 2.75, at least 3, at least 3.25, at least 3.5, at least 3.75, or at least 4 times the diameter of the initial chamber (for example, when the carrier gas and / or the raw material is electrically heated) of the reactor (or is at least 2.25, at least 2.5, at least 2.75, at least 3, at least 3.25, at least 3.5, at least 3.75, or at least 4 times the diameter of the reactor into which the first carbon black raw material was introduced or injected).

[0118] The low yield carbon black feedstock may be introduced at location 8 and / or 59 via one or more injectors.

[0119] Once the raw materials (first carbon black raw material and low yield carbon black raw material) have been combined with the heated gas stream, the methods of the present invention generally include the step of cooling the reaction.

[0120] The reaction is interrupted in the cooling zone of the reactor (see 62 in [Fig. 6]). As illustrated in [Fig. 6], the cooling 62 is located downstream of the last raw material injection zone and sprays a cooling fluid, such as water, into the stream of newly formed carbon black particles. Typically, the cooling serves to cool the carbon black particles and reduce the temperature of the gas stream and the reaction rate. The distance 67 corresponds to the distance between the start of the last raw material injection point and the cooling point 62, and varies depending on the position of the cooling. Optionally, the cooling can be carried out in stages, or take place at several points in the reactor. Pressure spraying, gas atomization spraying, or any other cooling technique can also be used.With respect to the complete cooling of the reactions to form carbon black, any means known to those skilled in the art for cooling the reaction downstream of the introduction of the carbon black raw materials may be used. For example, a cooling fluid, which may be water or any other suitable fluid, may be injected to stop the chemical reaction.

[0121] After cooling, the cooled gases and carbon black pass downstream to any conventional cooling and separation means, whereby the product is recovered. Separation of the carbon black from the gas stream is readily accomplished by conventional means such as a precipitator, cyclone separator, bag filter, or any other means known to those skilled in the art. Once the carbon black has been separated from the gas stream, it may optionally be subjected to a pelletizing step.

[0122] For any of the processes of the present invention, optionally, the carbon black produced is not a carbon black that has a core and a topcoat.

[0123] For any of the processes of the present invention, optionally, the carbon black is formed entirely in situ in the reactor.

[0124] Optionally, one or more of the carbon black raw materials or other components used in the processes of the present invention may be preheated prior to introduction into the reactor. Suitable preheating temperatures and / or techniques may be used in the present invention as shown, for example, in U.S. Patent No. 3,095,273 issued June 25, 1963 to Austin; U.S. Patent No. 3,288,696 issued November 29, 1966 to Orbach; U.S. Patent No. 3,984,528 issued October 5, 1976 to Cheng et al.; U.S. Patent No. 4,315,901 issued February 16, 1982 to Cheng et al.; U.S. Patent No. 4,765,964 issued August 23, 1988 to Gravley et al.; U.S. Patent No. 5,997,837 issued December 7, 1999 to Lynum et al.; U.S. Patent No. 7,097,822 issued August 29, 2006 to Godai et al.; U.S. Patent No. 8,871,173B2 issued October 28, 2014 to Nester et al., or CA 682982.Alternatively or additionally, the low yield carbon black feedstock may be preheated to a temperature higher than is typical for a higher yield feedstock. For example, the low yield carbon black feedstock may be heated to a temperature above 600°C, such as 600 to 800°C, even at ambient pressure. Since the low yield carbon black feedstock has a reduced asphaltene concentration, heating to such a high temperature does not generate significant amounts of coke or other solid species other than carbon black. Alternatively or additionally, one or more of the carbon black feedstocks may be combined with an adjunct fluid prior to introduction into the reactor, as described, for example, in U.S. Patent No. 10,829,642 to Unrau.

[0125] Optionally, the method is carried out in the absence of at least one substance which is or contains at least one element of group IA or IIA (or an ion thereof) of the periodic table.

[0126] Optionally, in any of the methods of the present invention, the The method may comprise the step of introducing at least one substance which is or contains at least one Group IA or IIA element (or an ion thereof) of the periodic table. Preferably, the substance contains at least one alkali metal or alkaline earth metal. This may be lithium, sodium, potassium, rubidium, cesium, francium, calcium, barium, strontium or radium, or combinations thereof. Mixtures of one or more of these components may be present in the substance. The substance may be a solid, a solution, a dispersion, a gas or any combination thereof. More than one substance having the same or a different Group IA or IIA metal may be used. If more than one substance is used, they may be added together, separately, sequentially or at different reaction locations.For the purposes of the present invention, the substance may be the metal (or metal ion) itself, a compound containing one or more of these elements, including a salt containing one or more of these elements, and the like. Preferably, the substance is capable of introducing a metal or metal ion into the ongoing reaction to form the carbon black product. For the purposes of the present invention, preferably, the substance is introduced before complete cooling, as described above. For example, the substance may be added at any point before complete cooling, including before the introduction of either of the two carbon black raw materials; during the introduction of either or both of the carbon black raw materials; after the introduction of all or some of the carbon black raw materials; or after the introduction of all of the raw materials, but before complete cooling.Several points of introduction of the substance may be used. The amount of Group IA or IIA metal that contains the substance may be any amount, as long as a carbon black product can be formed. For example, the amount of substance added may be such that 200 ppm or more of the Group IA or IIA element is present in the carbon black product formed at the end. Other amounts may be from about 200 ppm to about 5000 ppm or more, and other ranges may be from about 300 ppm to about 1000 ppm, or from about 500 ppm to about 1000 ppm of the Group IA or IIA element present in the carbon black product formed. These levels may depend on the metal ion concentration.As indicated, these amounts of Group IA or IIA element present in the formed carbon black product may be understood to be relative to one or more Group IA or IIA element(s) and are therefore a combined amount of the Group IA or IIA elements present in the formed carbon black product. The substance may be added in any manner, including by any conventional means. In other words, the substance may be added in the same way as a material. raw carbon black material is introduced. The substance may be added as a gas, liquid, or solid, or any combination thereof. The substance may be added at one or more points and may be added as a single stream or as a plurality of streams. The substance may be mixed with the raw material, a fuel, and / or an oxidizer before or during their introduction.

[0127] With respect to the carbon black formed by any of the methods of the present invention, the carbon black formed or produced may be any reinforcing or non-reinforcing grade carbon black. The reinforcing grades may be, for example, N110, N121, N220, N231, N234, N299, N326, N330, N339, N347, N351, N358 and N375. The semi-reinforcing grades may be, for example, N539, N550, N650, N660, N683, N762, N765, N774, N787 and / or N990.

[0128] Carbon black may be characterized by a specific surface area, structure, aggregate size, shape, and distribution; and / or the chemical and physical properties of the surface. The properties of carbon black are determined analytically by tests known in the art. For example, nitrogen adsorption surface area and statistical thickness surface area (STSA), another measure of surface area, are determined by nitrogen adsorption according to test procedure ASTM D6556. Iodine value may be measured using procedure ASTM D1510. The "structure" of carbon black describes the size and complexity of the carbon black aggregates formed by the fusion of primary carbon black particles with each other.As used herein, carbon black structure can be measured as the oil absorption number (OAN) for unground carbon black, expressed in milliliters of oil per 100 grams of carbon black, according to the procedure defined in ASTM D2414. Compressed oil absorption number (COAN) measures the portion of the carbon black structure that is not readily altered by the application of mechanical stress. COAN is measured according to ASTM D3493. Aggregate size distribution (ASD) is measured according to the ISO 15825 method using disk centrifuge photosedimentometry, with a BL DCP model manufactured by Brookhaven Instruments.

[0129] Carbon black materials that exhibit suitable properties for a specific application may be selected and defined by ASTM standards (see, for example, ASTM D1765 Standard Classification System for Carbon Blacks Used in Rubber Products), such as N100, N200, N300, N500, N600, N700, N800, or N900 carbon blacks, NI 10, N121, N220, N231, N234, N299, N326, N330, N339, N347, N351, N358, N375, N539, N550, N650, N660, N683, N762, N765, N774, N787, or N990 carbon blacks, or other commercial grade materials.

[0130] The carbon black may have any STS A of, for example, 5 m2 / g to 250 m2 / g, 11 m2 / g to 250 m2 / g, 20 m2 / g to 250 m2 / g or more, for example, at least 70 m2 / g, such as 70 m2 / g to 250 m2 / g, or 80 m2 / g to 200 m2 / g or 90 m2 / g to 200 m2 / g, or 100 m2 / g to 180 m2 / g, 110 m2 / g to 150 m2 / g, 120 m2 / g to 150 m2 / g and the like. Optionally, the carbon black may have an iodine value (12 No) of between about 5 and about 35 mg I2 / g (according to ASTM D1510).

[0131] The carbon black particles described herein may have a BET, measured by the Brunauer / Emmett / Teller (BET) technique according to ASTM procedure D6556, of between 5 m2 / g and 300 m2 / g, such as between 50 m2 / g and 300 m2 / g, such as between 100 m2 / g and 300 m2 / g. The BET surface area may be between about 100 m2 / g and about 200 m2 / g or between about 200 m2 / g and about 300 m2 / g.

[0132] The oil adsorption index (OAN) may be between 40 ml / 100g and 200 ml / 100g, such as between 60 ml / 100g and 200 ml / 100g, such as between 80 ml / 100g and 200 ml / 100g, such as between 100 ml / 100g and 200 ml / 100g or between 120 ml / 100g and 200 ml / 100g, ml / 100g 140 ml / 100g and 200 ml / 100g ml / 100g, 160 and 200 ml / 100g, or between 40 ml / 100g and 150 ml / 100g or 40 ml / 100g and 150 ml / 100g.

[0133] The CO AN can be between about 40 ml / 100 g and about 150 ml / 100 g, such as between about 55 ml / 100g and about 150 ml / 100g, such as between about 80 ml / 100g and about 150 ml / 100g, or between about 80 ml / 100g and about 120 ml / 100g.

[0134] The carbon black may be a carbon product that contains silicon-containing species and / or metal-containing species and the like, which may be obtained by including the additional step of introducing these species with or in addition to one or both of the carbon black feedstocks. The carbon black may be, for the purposes of the present invention, a multi-phase aggregate comprising at least one carbon phase and at least one metal-containing species phase or one silicon-containing species phase (also referred to as "silicon-treated carbon black, such as Cabot Corporation's ECOBLAK™ materials).

[0135] As indicated, the carbon black may be a rubber black, and more particularly a reinforcing grade of carbon black or a semi-reinforcing grade of carbon black.

[0136] Optionally, the carbon black of the present invention may have functional groups or chemical groups (e.g., derived from small molecules or polymers, ionic or nonionic) that are directly attached to the carbon surface (e.g., covalently). Examples of functional groups that may be directly attached (e.g., covalently) to the surface of the carbon black particles and methods of performing the surface modification are described, for example, in U.S. Patent No. 5,554,739 issued by Belmont on September 10, 1996 and U.S. Patent No. 5,922,118 to Johnson et al. issued on July 13, 1999. Illustratively, a surface-modified carbon black that may be used herein is obtained by treating carbon black with diazonium salts formed by the reaction of sulfanilic acid or para-aminobenzoic acid (PA B A) with HCl and NaNO2. Surface modification by sulfanilic acid or para-aminobenzoic acid processes using diazonium salts, for example, results in a carbon black that has effective amounts of hydrophilic functional groups on the carbon layer.

[0137] The surface of the carbon black may be modified according to U.S. Patent No. 8,975,316 to Belmont et al..

[0138] Other techniques that can be used to provide functional groups attached to the surface of carbon black are described in U.S. Patent No. 7,300,964 issued to Niedermeier et al. on November 27, 2007.

[0139] Oxidized (modified) carbon black may be prepared in a manner similar to that used on carbon black, as described, for example, in U.S. Patent No. 7,922,805 issued to Kowalski et al. on April 12, 2011, and in U.S. Patent No. 6,471,763 issued to Karl on October 29, 2002. An oxidized carbon black is a carbon black that has been oxidized using an oxidizing agent to introduce ionic and / or ionizable groups to the surface. These particles may have a higher degree of oxygen-containing groups on the surface.Oxidizing agents include, but are not limited to, oxygen, ozone, peroxides such as hydrogen peroxide, persulfates, such as sodium and potassium persulfate, hypohalites such as sodium hypochlorite, oxidizing acids such as nitric acid, and transition metal-containing oxidants, such as permanganate salts, osmium tetroxide, chromium oxides, or ammonium nitrate. Mixtures of oxidants may also be used, and more particularly mixtures of gaseous oxidants such as oxygen and ozone. Other surface modification methods, such as chlorination and sulfonylation, may also be used to introduce ionic or ionizable groups. The carbon black may be surface modified by any method known to those skilled in the art. For example, carbon black can be heat treated, as described in US Patent 10767028.

[0140] Carbon black can be used in various applications, such as as reinforcement in rubber products, such as tire components.

[0141] Carbon black can be incorporated into rubber products, used, for example, for treads, and more particularly treads intended for automobile, light vehicle, truck and bus tires, tires off-road (“OTR”) tires, aircraft tires and the like; undertreads; bonding layers; sidewalls; toe rubber for retreaded tires; and other tire-related uses.

[0142] In other applications, the particles may be used in industrial rubber products, such as engine mounts, hydraulic mounts, seismic bearings and isolators, tank tracks or treads, mining belts, hoses, seals, blades, weather stripping, dampers, anti-vibration parts, and the like.

[0143] Carbon black may be alternatively or additionally added to first reinforcing agents for tire components and / or other industrial rubber-related end uses. Carbon black may be combined with natural and / or synthetic rubber in a suitable dry or wet mixing process that relies on an internal batch mixer, a continuous mixer, or a rolling mill.

[0144] Alternatively, the carbon black may be blended into rubber via a liquid masterbatch process. For example, a slurry that contains the particles described herein may also be combined with an elastomeric latex in a tank and then coagulated by the addition of a coagulant, such as an acid, using the techniques described in U.S. Patent No. 6,841,606.

[0145] Carbon black may be introduced according to U.S. Patent No. 6,048,923 issued to Mabry et al. on April 11, 2000. For example, a method of preparing an elastomeric masterbatch may involve simultaneously supplying a particulate filler-based fluid and an elastomeric latex-based fluid to a mixing zone of a coagulum reactor. A coagulum zone extends from the mixing zone, preferably gradually increasing transversely, in the downstream direction between an inlet end and a discharge end. The elastomeric latex may be natural or synthetic and the particulate filler comprises, consists essentially of, or consists of the material described above. The particulate filler is supplied to the mixing zone preferably as a continuous, high-velocity jet of injected fluid, while the latex fluid is supplied at a low velocity.The velocity, flow rate, and particle concentration of the particulate filler fluid are sufficient to cause high shear mixing of the latex fluid, and low turbulence of the mixing in at least an upstream portion of the coagulum zone so as to coagulate substantially all of the elastomeric latex with the particulate filler prior to the discharge end. Substantially complete coagulation can occur without the need for an acid- or salt-based coagulating agent. As described in U.S. Patent No. 6,075,084, additional elastomer can be added to the material emerging from the discharge end of the coagulum reactor. As described in U.S. Patent No. 6,929,783, the coagulum can then be supplied to extrusion dewatering equipment. Other examples of suitable masterbatch processes are described in U.S. Patent No. 6,929,783 to Chung et al.; US Patent Application 2012 / 0264875A1 to Berriot et al.; US Patent Application 2003 / 0088006A1 to Yanagisawa et al.; and EP 1,834,985 B1 published by Yamada et al.

[0146] Carbon black may be evaluated in a suitable rubber formulation, using natural or synthetic rubber. Suitable amounts of carbon black to be used may be determined by routine experimentation and calculation, taking into account factors such as typical loadings of standard ASTM blacks in comparable manufacturing processes, parameters specific to the techniques and / or equipment used, the presence or absence of other additives, the desired properties of the final product, etc.

[0147] The performance of carbon black as a reinforcing agent for rubber compounds can be evaluated by determining, for example, the performance of a rubber composition that uses the particles relative to the performance of a comparative rubber composition that is similar in all respects except for the use of a grade of carbon black suitable for the given application. In other approaches, values ​​obtained for compositions prepared according to the invention can be compared with values ​​known in the art and related to the desired parameters in a given application.

[0148] Green rubber tests, cure tests, and cured rubber tests may be suitable. Among suitable green rubber tests, ASTM D4483 defines a test method for the ML1+4 Mooney viscosity test at 100°C. The scorch time is measured according to ASTM D4818.

[0149] The curing curve is obtained by a rubber analyzer (RPA2000) at 0.5°, 100 cpm and 150C (NR) - 160C (SBR) according to ASTM D5289.

[0150] The performance characteristics of the cured samples can be determined using a series of suitable tests. Tensile strength, elongation at break and resistance to different strains (e.g. 100% and 300%) are obtained via Method A of ASTM D412. Dynamic mechanical properties, such as storage modulus, loss modulus and tan δ are obtained using a strain test at 10 Hz, 60C and different strain amplitudes between 0.1% and 63%. Shore A hardness is measured according to ASTM D2240. Tear resistance of “Die B” type cured rubber samples is measured according to ASTM D624.

[0151] The undispersed surface area is calculated by analyzing images obtained by reflection mode optical microscopy for cured rubber compounds of a cross-sectional area cut, according to different processes. Dispersion can also be represented by the Z value (measured, after crosslinking, according to the process described by S. Otto et al in Kautschuk Gummi Kunststoffe, 58 Jahrgang, NR 7-8 / 2005, article entitled "New Reference value for the description of Filler Dispersion with the Dis-pergrader 1000NT". ISO 11345 defines visual methods for rapid and comparative assessment of the degree of macrodispersion of carbon black and carbon black / silica in rubber.

[0152] Abrasion resistance is quantified as an index based on the abrasion loss of a rubber cured by a Cabot (Lambourn type) abrasion machine. Attractive abrasion resistance results may indicate advantageous wear properties. Good hysteresis results may be related to low rolling resistance (and therefore better fuel economy) for motor vehicle tire applications, reduced heat buildup, extended tire, tread and casing durability, fuel savings for motor vehicles, etc.

[0153] The iodine value (12 No.) is determined according to the ASTM D1510 test procedure. The STSA (statistical thickness area) is determined based on the ASTM D-5816 test procedure (measured by nitrogen adsorption). The oil adsorption value is determined based on the ASTM D2414 standard. The compressed oil adsorption value is determined based on the ASTM D3493 standard (e.g., D3493-20).

[0154] Unless otherwise stated, all proportions of materials described as percentages herein are by weight percentages.

[0155] The present invention will be further clarified by the following examples, which are intended to be exemplary only.

[0156] The present invention comprises the following aspects / embodiments / features, in any order and / or any combination:

[0157] 1. Process for manufacturing a carbon black comprising:

[0158] - electrical heating of a carrier gas to form a heated carrier gas of whereby pyrolysis of at least a portion of a carbon black feedstock occurs in a carbon black reactor by contact with said heated carrier gas, wherein the carbon black feedstock comprises at least a first carbon black feedstock and at least one low yield carbon black feedstock;

[0159] - the combination of the at least one first carbon black raw material with said heated carrier gas to form a reaction stream, wherein the at least one first carbon black feedstock comprises at least 10% by weight of the total carbon black feedstock;

[0160] - the combination, downstream, of at least one carbon black raw material with low yield with said reaction stream present to form carbon black, wherein the at least one low yield carbon black feedstock comprises at least 10% by weight of the total carbon black feedstock; and

[0161] - the recovery of carbon black in the reaction stream, in which the first Carbon black raw material is a liquid at room temperature and pressure, and has the following properties: - a US Bureau of Mines Correlation Index (BMCI) > 100, - an atomic ratio H:C < 1.23, and - a specific gravity > 1.02; and wherein the low yield carbon black feedstock has at least one of the following properties:

[0162] - a US Bureau of Mines Correlation Index (BMCI) < 100, or

[0163] - an atomic ratio H:C > 1.23, or

[0164] - a specific gravity < 1.02, or

[0165] - is a gas at room temperature and pressure, and

[0166] wherein the at least one low yield carbon black feedstock is present in an amount of between 10% by weight and 90% by weight, based on said total carbon black raw material, and the at least one first carbon black raw material is present in an amount of between 10% by weight and 90% by weight based on said total carbon black raw material.

[0167] 2. Process for manufacturing a carbon black comprising:

[0168] - electrical heating of a carrier gas to form a heated carrier gas of whereby pyrolysis of at least a portion of a carbon black feedstock occurs in a carbon black reactor by contact with said heated carrier gas, wherein the carbon black feedstock comprises at least a first carbon black feedstock and at least one low yield carbon black feedstock;

[0169] - the combination of the at least one first carbon black raw material and of the at least one low yield carbon black feedstock as a mixture or separate additions at the same or substantially the same location, with said heated carrier gas to form a reaction stream, wherein the at least one first carbon black feedstock comprises at least 10% by weight of the total carbon black feedstock and the at least one low yield carbon black feedstock comprises at least 10% by weight of the total carbon black feedstock; and

[0170] - the recovery of carbon black in the reaction stream, in which the first Carbon black raw material is a liquid at room temperature and pressure, and has the following properties: - a US Bureau of Mines Correlation Index (BMCI) > 100, - an H:C atomic ratio < 1.23, and - a specific gravity > 1.02; and wherein the low yield carbon black feedstock has at least one of the following properties:

[0171] - a US Bureau of Mines Correlation Index (BMCI) < 100, or

[0172] - an atomic ratio H:C > 1.23, or

[0173] - a specific gravity < 1.02, or

[0174] - is a gas at room temperature and pressure, and

[0175] wherein the at least one low yield carbon black feedstock is present in an amount of between 10% by weight and 90% by weight, based on said total carbon black raw material, and the at least one first carbon black raw material is present in an amount of between 10% by weight and 90% by weight based on said total carbon black raw material.

[0176] 3. Process for manufacturing a carbon black comprising:

[0177] - electrical heating of at least one first raw material of carbon black carbon to form a reaction stream such that pyrolysis of at least a portion of the at least one first carbon black feedstock occurs in a carbon black reactor, wherein the at least one first carbon black feedstock comprises at least 10% by weight of the total carbon black feedstock;

[0178] - the combination, downstream, of at least one carbon black raw material with low yield with said reaction stream present to form carbon black, wherein the at least one low yield carbon black feedstock comprises at least 10% by weight of the total carbon black feedstock; and

[0179] - the recovery of carbon black in the reaction stream, in which the first Carbon black raw material is a liquid at room temperature and pressure, and has the following properties: - a US Bureau of Mines Correlation Index (BMCI) > 100, - an atomic ratio H:C < 1.23, and - a specific gravity > 1.02; and wherein the low yield carbon black feedstock has at least one of the following properties:

[0180] - a US Bureau of Mines Correlation Index (BMCI) < 100, or

[0181] - an atomic ratio H:C > 1.23, or

[0182] - a specific gravity < 1.02, or

[0183] - is a gas at room temperature and pressure, and

[0184] wherein the at least one low yield carbon black feedstock is present in an amount of between 10 wt% and 90 wt%, based on said total carbon black feedstock, and the at least one first carbon black feedstock is present in an amount of between 10 wt% and 90 wt% based on said total carbon black feedstock.

[0185] 4. Method according to any one of the embodiments / features / aspects preceding or following, further comprising electrically heating the at least one low yield carbon black feedstock.

[0186] 5. Method according to any one of the embodiments / features / aspects preceding or following, wherein electrically heating the at least one low yield carbon black feedstock comprises heating the low yield carbon black feedstock to a temperature between 600 and 800°C.

[0187] 6. Method according to any one of the embodiments / features / aspects preceding or following, further comprising electrically heating at least one first carbon black feedstock and the at least one low yield carbon black feedstock.

[0188] 7. Method according to any one of the embodiments / features / aspects preceding or following, wherein said electric heating is carried out using an arc.

[0189] 8. Method according to any one of the embodiments / features / aspects preceding or following, wherein said electric heating is carried out using a resistive or induction heating element.

[0190] 9. Method according to any one of the embodiments / features / aspects preceding or following, wherein the heating element is magnesium oxide or yttrium-stabilized zirconia.

[0191] 10. Method according to any one of the embodiments / characteristics- preceding or following characteristics / aspects, wherein said heated carrier gas has a temperature greater than 2000°C.

[0192] 11. Method according to any one of the embodiments / characteristics- preceding or following characteristics / aspects, wherein said electrical heating is carried out using an induction or microwave process which prevents any direct contact between an electrode and a carrier gas or the carbon black raw material.

[0193] 12. Method according to any one of the embodiments / characteristics- preceding or following characteristics / aspects, wherein said electric heater is carried out using a plasma arc or a heating element in direct contact with said carbon black raw material.

[0194] 13. Method according to any one of the embodiments / characteristics- preceding or following characteristics / aspects, wherein the low yield carbon black feedstock is at least one of the following: a. said US Bureau of Mines Correlation Index (BMCI) < 95, or b. said gas at ambient temperature and pressure, or c. said atomic ratio H:C > 1.3, or d. said specific gravity < 1. 14. A method according to any one of the preceding or following embodiments / features / aspects, wherein the low yield carbon black feedstock has said specific gravity of 1.02 or less.

[0195] 15. Method according to any one of the embodiments / characteristics- preceding or following characteristics / aspects, wherein said low-yield carbon black feedstock comprises at least one of the following: an oil derived from a vegetable or any other plant, bio-based ethanol, a wax or resin produced by a plant or an animal, an oil derived from animal fat, an algal oil, an oil derived from the pyrolysis of sewage sludge or agricultural waste, a by-product liquid from the processing of a biogenic material, a liquid produced by hydrothermal liquefaction of a biomaterial, a raw liquid resin, a liquid resin rosin, a liquid resin pitch, or a liquid resin fatty acid, an oil produced from recycled materials, an oil derived from the pyrolysis of substandard, discarded, or end-of-life tires, an oil derived from the pyrolysis of discarded or recycled plastic or rubber products, an oil derived from the pyrolysis of municipal solid waste,or an oil derived from the pyrolysis of biomass, or any combination of the above.

[0196] 16. Method according to any one of the embodiments / characteristics- preceding or following characteristics / aspects, wherein the at least one first carbon black feedstock comprises one or more of settling grease, settled oily sludge, coal tar, a coal tar derivative, an ethylene cracking unit residue, or a phenol cracking unit residue.

[0197] 17. Method according to any one of the embodiments / characteristics- preceding or following characteristics / aspects, wherein the first carbon black raw material is a fraction obtained from the distillation of tire pyrolysis oil.

[0198] 18. Method according to any one of the embodiments / characteristics- previous or following characteristics / aspects, in which the raw material of black low yield carbon represents 50 to 90% by weight of a total raw material used in the said process.

[0199] 19. Method according to any one of the embodiments / characteristics- 20. A method according to any one of the preceding or following embodiments / features / aspects, wherein the low yield carbon black feedstock comprises 60-90% by weight of a total feedstock used in said process. 20. A process according to any one of the preceding or following embodiments / features / aspects, wherein the carbon black reactor has a first chamber in which said electrical heating occurs and a bottleneck downstream of the first chamber and a reaction chamber downstream of the bottleneck and a cooling zone downstream of the reaction chamber, and wherein the first carbon black feedstock is injected into said bottleneck and the low yield carbon black feedstock is injected after said bottleneck.

[0200] 21. Method according to any one of the embodiments / characteristics- preceding or following characteristics / aspects, wherein said carbon black reactor comprises a second bottleneck downstream of said reaction chamber and before said cooling zone, and said low yield carbon black feedstock is injected into said second bottleneck.

[0201] 22. Method according to any one of the embodiments / characteristics- preceding or following characteristics / aspects, wherein said at least first carbon black feedstock is introduced into said carbon black reactor at a first location and at least one separate location downstream of the first location.

[0202] 23. Method according to any one of the embodiments / characteristics- preceding or following characteristics / aspects, wherein the amount of first carbon black raw material introduced at the first location is greater than 50% of the total amount of first carbon black raw material.

[0203] 24. Method according to any one of the embodiments / characteristics- preceding or following characteristics / aspects, wherein said at least one low yield carbon black feedstock is introduced into said carbon black reactor at at least two separate locations, with one of the separate locations being downstream of the other.

[0204] 25. Method according to any one of the embodiments / characteristics- preceding or following characteristics / aspects, wherein said at least one first carbon black raw material is a mixture which comprises less than 50% by weight of a low yield carbon black raw material based on the total weight of said first carbon black raw material.

[0205] 26. Method according to any one of the embodiments / characteristics- preceding or following characteristics / aspects, wherein said at least one first carbon black raw material is a mixture which comprises less than 5% by weight of a low yield carbon black raw material based on the total weight of said first carbon black raw material.

[0206] 27. Method according to any one of the embodiments / characteristics- preceding or following characteristics / aspects, wherein said at least one low yield carbon black feedstock is a mixture that comprises less than 50% by weight of a high yield carbon black feedstock based on the total weight of said low yield carbon black feedstock.

[0207] 28. Method according to any one of the embodiments / characteristics- preceding or following characteristics / aspects, wherein said at least one low yield carbon black feedstock is a mixture that comprises less than 5% by weight of a high yield carbon black feedstock based on the total weight of said low yield carbon black feedstock.

[0208] 29. Method according to any one of the embodiments / characteristics- preceding or following characteristics / aspects, wherein said low yield carbon black raw material has said BMCI value < 100.

[0209] 30. Method according to any one of the embodiments / characteristics- preceding or following characteristics / aspects, wherein said low yield carbon black raw material has said atomic ratio H:C > 1.23.

[0210] 31. Method according to any one of the embodiments / characteristics- preceding or following characteristics / aspects, wherein said low yield carbon black feedstock is said gas at ambient temperature and pressure.

[0211] 32. Method according to any one of the embodiments / characteristics- preceding or following characteristics / aspects, wherein said recovered carbon black is a carbon black of grade NI 10, N121, N220, N231, N234, N299, N326, N330, N339, N347, N351, N358, N375, N539, N550, N650, N660, N683, N762, N765, N774, N787 or N990.

[0212] 33. Carbon black made from any process according to one of any of the preceding or following embodiments / features / aspects,

[0213] The present invention may comprise any combination of the various features or embodiments above below as defined in the sentences and / or paragraphs herein. Any combination of features described herein is considered part of the present invention and no limitation is intended as to the features that may be combined.

[0214] Furthermore, when a quantity, concentration or any other value or parameter is stated as a range, a preferred range, or a list of preferable upper and preferable lower values, this is to be understood as specifically describing all ranges formed from any pair of any upper range limit or preferred value and any lower range limit or preferred value, whether or not the ranges are described separately. Where a range of numerical values ​​is cited herein, unless otherwise stated, the range is intended to include the end points thereof, and all integers and fractions that are part of that range. It is not intended that the scope of the invention be limited to the specific values ​​cited when defining a range.

[0215] Other embodiments of the present invention will be apparent to those skilled in the art from this description and from the practice of the present invention described herein. It is intended that this description and the examples be considered exemplary only, and that the true scope of the invention be indicated by the following claims and equivalents thereof.

Claims

1. Claims A process for manufacturing a carbon black comprising: - electrically heating a carrier gas to form a heated carrier gas such that pyrolysis of at least a portion of a carbon black feedstock occurs in a carbon black reactor upon contact with said heated carrier gas, wherein the carbon black feedstock comprises at least a first carbon black feedstock and at least one low yield carbon black feedstock; - combining the at least one first carbon black raw material with said heated carrier gas to form a reaction stream, wherein the at least one first carbon black raw material comprises at least 10% by weight of the total carbon black raw material; - combining, downstream, at least one low yield carbon black feedstock with said present reaction stream to form carbon black, wherein the at least one low yield carbon black feedstock comprises at least 10% by weight of the total carbon black feedstock; and - the recovery of carbon black from the reaction stream, wherein the first carbon black raw material is a liquid at ambient temperature and pressure, and has the following properties: - a US Bureau of Mines Correlation Index (BMCI) > 100, - an atomic ratio H:C < 1.23, and - a specific gravity > 1.02; and wherein the low yield carbon black feedstock has at least one of the following properties: - a US Bureau of Mines Correlation Index (BMCI) < 100, or - an atomic ratio H:C > 1.23, or - a specific gravity < 1.02, or - is a gas at room temperature and pressure, and wherein the at least one low yield carbon black feedstock is present in an amount of between 10 wt% and 90 wt%, based on said total carbon black feedstock, and the at least one first carbon black feedstock is present in an amount of between 10 wt% and 90 wt% based on said total carbon black feedstock.

2. carbon. A process for manufacturing a carbon black comprising: - electrically heating a carrier gas to form a heated carrier gas such that pyrolysis of at least a portion of a carbon black feedstock occurs in a carbon black reactor upon contact with said heated carrier gas, wherein the carbon black feedstock comprises at least a first carbon black feedstock and at least one low yield carbon black feedstock; - combining the at least one first carbon black feedstock and the at least one low yield carbon black feedstock as a mixture or as separate additions at the same or substantially the same location, with said heated carrier gas to form a reaction stream, wherein the at least one first carbon black feedstock comprises at least 10% by weight of the total carbon black feedstock and the at least one low yield carbon black feedstock comprises at least 10% by weight of the total carbon black feedstock; and - the recovery of carbon black from the reaction stream, wherein the first carbon black raw material is a liquid at ambient temperature and pressure, and has the following properties: - a US Bureau of Mines Correlation Index (BMCI) > 100, - an atomic ratio H:C < 1.23, and - a specific gravity > 1.02; and wherein the low yield carbon black feedstock has at least one of the following properties: - a US Bureau of Mines Correlation Index (BMCI) < 100, or - an atomic ratio H:C > 1.23, or - a specific gravity < 1.02, or - is a gas at room temperature and pressure, and wherein the at least one low yield carbon black feedstock is present in an amount of between 10 wt% and 90 wt%, based on said total carbon black feedstock, and the at least one first carbon black feedstock is present in an amount of between 10 wt% and 90 wt% based on said total carbon black feedstock.

3. A method of manufacturing a carbon black comprising: - electrically heating at least one first carbon black feedstock to form a reaction stream such that pyrolysis of at least a portion of the at least one first carbon black feedstock occurs in a carbon black reactor, wherein the at least one first carbon black feedstock comprises at least 10% by weight of the total carbon black feedstock; - combining, downstream, at least one low yield carbon black feedstock with said present reaction stream to form the carbon black, wherein the at least one low yield carbon black feedstock comprises at least 10% by weight of the total carbon black feedstock;and - recovering carbon black from the reaction stream, wherein the first carbon black feedstock is a liquid at room temperature and pressure, and has the following properties: - a US Bureau of Mines Correlation Index (BMCI) > 100, - an H:C atomic ratio < 1.23, and - a specific gravity > 1.02;and wherein the low yield carbon black feedstock has at least one of the following properties: - a US Bureau of Mines Correlation Index (BMCI) < 100, or - an H:C atomic ratio > 1.23, or - a specific gravity < 1.02, or - is a gas at room temperature and pressure, and wherein the at least one low yield carbon black feedstock is present in an amount of between 10 wt% and 90 wt%, based on said total carbon black feedstock, and the at least one first carbon black feedstock is present in an amount of between 10 wt% and 90 wt% based on said total carbon black feedstock.;

4. A method according to any preceding claim, further comprising electrically heating the at least one low yield carbon black feedstock.

5. The method of claim 4, wherein electrically heating the at least one low yield carbon black feedstock comprises heating the carbon black feedstock to low efficiency at a temperature between 600 and 800°C.

6. The method of claim 1 or 2, further comprising electrically heating at least one first carbon black feedstock and the at least one low yield carbon black feedstock.

7. A method according to claim 1 or 2, wherein said electrical heating is carried out using an arc.

8. A method according to claim 1 or 2, wherein said electrical heating is carried out using a resistive or induction heating element.

9. The method of claim 8, wherein the heating element is magnesium oxide or yttrium-stabilized zirconia.

10. A method according to any one of claims 1 to 9, wherein said heated carrier gas has a temperature greater than 2000°C.

11. A method according to any one of claims 1 to 3, wherein said electrical heating is carried out using an induction or microwave method which prevents direct contact between an electrode and a carrier gas or the carbon black raw material.

12. The method of claim 3, wherein said electrical heating is performed using a plasma arc or a heating element in direct contact with said carbon black raw material.

13. A method according to any preceding claim, wherein the low yield carbon black feedstock is at least one of the following: i. said US Bureau of Mines Correlation Index (BMCI) < 95, or ii. said gas at room temperature and pressure, or iii. said H:C atomic ratio > 1.3, or iv. said specific gravity < 1.

0.

14. A method according to any preceding claim, wherein the low yield carbon black raw material has said specific gravity of 1.02 or less.

15. A method according to any preceding claim, wherein said low yield carbon black raw material comprises at least one of the following: an oil derived from a vegetable or any other plant, bio-based ethanol, a wax or a resin. produced by a plant or animal, an oil derived from animal fat, an algal oil, an oil derived from the pyrolysis of sewage sludge or agricultural waste, a by-product liquid from the processing of a biogenic material, a liquid produced by hydrothermal liquefaction of a biomaterial, a raw liquid resin, a liquid resin rosin, a liquid resin pitch, or a liquid resin fatty acid, an oil produced from recycled materials, an oil derived from the pyrolysis of non-standard, discarded, or end-of-life tires, an oil derived from the pyrolysis of discarded or recycled plastic or rubber products, an oil derived from the pyrolysis of municipal solid waste, or an oil derived from the pyrolysis of biomass, or any combination of the foregoing.

16. A method according to any preceding claim, wherein the at least one first carbon black raw material comprises one or more of settling grease, settled oily sludge, coal tar, a coal tar derivative, an ethylene cracking unit residue, or a phenol cracking unit residue.

17. A method according to any preceding claim, wherein the first carbon black raw material is a fraction obtained from the distillation of tire pyrolysis oil.

18. A process according to any preceding claim, wherein the low yield carbon black raw material accounts for 50 to 90% by weight of a total raw material used in said process.

19. A process according to any preceding claim, wherein the low yield carbon black raw material comprises 60 to 90% by weight of a total raw material used in said process.

20. A method according to any preceding claim, wherein the carbon black reactor has a first chamber in which said electrical heating occurs and a bottleneck downstream of the first chamber and a reaction chamber downstream of the bottleneck and a cooling zone downstream of the reaction chamber, and wherein the first carbon black feedstock is injected into said bottleneck and the low yield carbon black feedstock is injected after said bottleneck.

21. The method of claim 20, wherein said carbon black reactor comprises a second bottleneck downstream of said reaction chamber and before said cooling zone, and said low yield carbon black feedstock is injected into said second bottleneck.

22. A method according to any preceding claim, wherein said at least one first carbon black feedstock is introduced into said carbon black reactor at a first location and at least one separate location downstream of the first location.

23. The method of claim 22, wherein the amount of first carbon black raw material introduced at the first location is greater than 50% of the total amount of the first carbon black raw material.

24. A method according to any preceding claim, wherein said at least one low yield carbon black feedstock is introduced into said carbon black reactor at at least two separate locations, with one of the separate locations being downstream of the other.

25. A method according to any preceding claim, wherein said at least one first carbon black raw material is a mixture that comprises less than 50% by weight of a low yield carbon black raw material based on the total weight of said first carbon black raw material.

26. A method according to any preceding claim, wherein said at least one first carbon black feedstock is a mixture that comprises less than 5% by weight of a low yield carbon black feedstock based on the total weight of said first carbon black feedstock.

27. ​​A method according to any preceding claim, wherein said at least one low yield carbon black feedstock is a mixture that comprises less than 50% by weight of a high yield carbon black feedstock based on the total weight of said low yield carbon black feedstock.

28. A method according to any preceding claim, wherein said at least one low yield carbon black feedstock is a mixture which comprises less than 5% by weight of a high yield carbon black raw material based on the total weight of said low yield carbon black raw material.

29. A method according to any preceding claim, wherein said low yield carbon black raw material has said BMCI value < 100.

30. A method according to any preceding claim, wherein said low yield carbon black raw material has said H:C atomic ratio > 1.

23.

31. A method according to any preceding claim, wherein said low yield carbon black feedstock is said gas at ambient temperature and pressure.

32. A method according to any preceding claim, wherein said recovered carbon black is a carbon black of grade NI 10, N121, N220, N231, N234, N299, N326, N330, N339, N347, N351, N358, N375, N539, N550, N650, N660, N683, N762, N765, N774, N787 or N990.

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