Sustainable Carbon Black Formulation

Abstract

The present invention relates to a reactor and a method for producing carbon black. Hydrogen is used as a carrier gas as well as a fuel to enhance the yield of carbon black. Furthermore, plasma can be applied downstream of the evaporation zone of the carbon black reactor system or downstream of the feedstock injection (in case of gaseous feedstock) to generate hydrogen radicals and hydrogen ions that further enhance the carbon black formation.

Description

[Technical field]

[0001] The present invention relates to a reactor and a method for producing carbon black. Hydrogen is used as a carrier gas as well as a fuel to enhance the yield of carbon black. Furthermore, plasma can be applied downstream of the evaporation zone of the carbon black reactor system or downstream of the feedstock injection (in case of gaseous feedstock) to generate hydrogen radicals and hydrogen ions that further enhance the carbon black formation. [Background technology]

[0002] Standard carbon black formulations use air as the carrier gas. Approximately 50% of the exergy of the input stream can be converted to carbon black. Currently, 50% of the exergy is either destroyed or converted to low heat generating gas streams and utilized in the Clausius-Rankine process with very low efficiency. High content of inert gases such as nitrogen makes the use of the tail gas economically unattractive.

[0003] Carbon black formation can be separated into distinct process steps including increasing the temperature of the feedstock to pyrolysis temperature (and vaporization of the feedstock if it is a liquid), pyrolysis of the feedstock to unsaturated species such as acetylene and aromatic-containing intermediates, nucleation, surface growth, and agglomeration.

[0004] Sustainable carbon black feedstocks (i.e., feedstocks for carbon black), such as aliphatic oils, renewable carbon black feedstocks and biomass-based feedstocks, have a high content of aliphatic C-C bonds and a low content of aromatic C-C bonds. The aliphatic C-C bonds are weak compared to C-H or aromatic C-C bonds. Therefore, primarily the C-C bonds of sustainable carbon black feedstocks are broken, but the cleavage of C-H bonds is favored to obtain unsaturated species for the formation of carbon black.

[0005] It would therefore be desirable to provide a method and reactor system for forming carbon black that overcomes the problems discussed above. In particular, it would be desirable to provide a method and reactor system for forming carbon black in which the tail gas can be easily separated and reused as a carrier gas or utilized as a highly exothermic gas stream. Additionally, it would be desirable to positively influence the formation of carbon black and use sustainable carbon black feedstocks.

[0006] Surprisingly, it has been found that hydrogen (H2) can be used as a fuel and carrier gas in the methods and reactor systems for producing carbon black, particularly in furnace processes or reactor systems thereof, and can therefore be used to replace air streams in conventional carbon black production processes. Hydrogen increases the level of hydrogen radicals in the gas stream, accelerating the pyrolysis reaction of the feedstock. Accelerating the pyrolysis reaction reduces the effect of backmixing of the gas stream. This increases the amount of nucleation and therefore the yield of carbon black. Furthermore, the increased amount of hydrogen radicals allows the use of sustainable carbon black feedstocks, such as biomass-based feedstocks, aliphatic oils, or aliphatic materials in general.

[0007] Additionally, it has been found that the tail gas generally contains hydrogen, CO, CO2 and water, and the hydrogen can be separated from the tail gas and recycled as a carrier material, utilized as a highly heat generating gas stream, or used as synthesis gas for the Fischer-Tropsch process.

[0008] Carbon black formation, especially with sustainable carbon black feedstocks, can be further positively influenced by using plasma to generate hydrogen radicals and hydrogen ions. Treatment with hydrogen radicals and hydrogen ions should be applied downstream of the evaporation zone of the reactor in case of liquid feedstocks and downstream of the feedstock injection in case of gaseous feedstocks. Summary of the Invention

[0009] The present invention relates to a method for producing carbon black, the method comprising: (a) injecting a first fluid into a combustion chamber of a reactor using an injection means; (b) feeding a second fluid into the combustion chamber through a conduit; (c) mixing the second fluid with the first fluid to obtain a combustion mixture; (d) combusting the combustion mixture in the combustion chamber to produce hot combustion gases; (e) receiving the hot combustion gases in a reaction chamber of the reactor subsequent to the combustion chamber; (f) injecting a feedstock for carbon black into the hot combustion gases received from the combustion chamber to obtain a hot reaction mixture comprising the feedstock for carbon black; and (g) reacting the hot reaction mixture in the reaction chamber to obtain a hot product mixture comprising carbon black, wherein the first fluid is an oxygen-containing gas and the second fluid is hydrogen, or the first fluid is hydrogen and the second fluid is an oxygen-containing gas.

[0010] The present invention further relates to a reactor system for producing carbon black, comprising a carbon black reactor comprising: (i) a combustion chamber for producing hot combustion gases by combustion of a combustion mixture comprising an oxygen-containing gas and hydrogen; (ii) a conduit for supplying a second fluid to the combustion chamber; (iii) an injection means for injecting a first fluid into the combustion chamber; and (iv) a reaction chamber subsequent to the combustion chamber, comprising a means for injecting a feedstock for carbon black (I) into the hot combustion gases received from the combustion chamber to form carbon black, wherein the first fluid is an oxygen-containing gas and the second fluid is hydrogen, or the first fluid is hydrogen and the second fluid is an oxygen-containing gas.

[0011] Further provided is carbon black produced according to the method of the invention and / or using a reactor system according to the invention. It has been found that a combustion mixture comprising an oxygen-containing gas and hydrogen and / or a high temperature combustion mixture comprising hydrogen can be used to produce carbon black, and that hydrogen can be used as a carrier gas and / or fuel for the production of carbon black. [Brief description of the drawings]

[0012] [Figure 1] Figure 1: Reactor for the production of carbon black including a plasma device downstream of the injection zone. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0013] As mentioned above, the present invention relates to a method and reactor system for the production of carbon black, the use of the produced carbon black, and a combustion mixture comprising hydrogen and an oxygen-containing gas / high temperature combustion mixture comprising hydrogen, and further to the use of hydrogen for the production of carbon black. The present invention will now be described with reference to the accompanying drawings, which are not intended to limit the scope and area of ​​the invention.

[0014] It should be noted that as used in this specification and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to "oxygen-containing gas" includes mixtures of oxygen-containing gases, reference to "fuel" includes mixtures of two or more such fuels, etc. Hydrogen refers to molecular hydrogen or dihydrogen, i.e., H2.

[0015] The method of producing carbon black includes (a) injecting a first fluid into a combustion chamber of a reactor using an injection means, (b) feeding a second fluid into the combustion chamber through a conduit, (c) mixing the second fluid with the first fluid to obtain a combustion mixture, (d) combusting the combustion mixture in the combustion chamber to produce a hot combustion gas, such as a hot hydrogen-containing combustion gas, (e) receiving the hot combustion gas in a reaction chamber of the reactor following the combustion chamber, (f) injecting a feedstock for carbon black into the hot combustion gas received from the combustion chamber to obtain a hot reaction mixture comprising the feedstock for carbon black, and (g) reacting the hot reaction mixture in the reaction chamber to obtain a hot product mixture comprising carbon black, wherein the first fluid is an oxygen-containing gas and the second fluid is hydrogen, or the first fluid is hydrogen and the second fluid is an oxygen-containing gas. Thus, the combustion mixture comprises an oxygen-containing gas and hydrogen.

[0016] The method utilizes hydrogen as both a fuel for carbon black production and as a carrier material. Conventional carbon black processes use natural gas, fuel oil, or other gaseous or liquid hydrocarbons. Generally, the fuel and oxygen-containing gas are fed to the combustion chamber in an amount that results in complete combustion of the fuel. Typically, air is used as the oxygen-containing gas to provide oxygen for the combustion of the fuel, and air is also used as a carrier material for carbon black production. A drawback of using air as a carrier material is that the resulting exhaust gas cannot be separated or used in another process. By using hydrogen not only as a fuel but also as a carrier material, it is possible to separate the remaining hydrogen from the exhaust gas and re-feed the hydrogen as a first or second fluid to the combustion chamber to obtain a highly heat-generating gas stream that can be used in further processes, or to use hydrogen or hydrogen / CO as synthesis gas. At the same time, hydrogen has a beneficial effect on carbon black production. By using hydrogen as a carrier material, the yield and uniform properties of carbon black can be increased. In particular, the yield of carbon black can be increased even when sustainable carbon black feedstocks, aliphatic oils, renewable feedstock materials or biomass-based feedstocks are used. Without being bound by theory, it is speculated that hydrogen radicals and / or hydrogen ions are formed which improve pyrolysis acceleration and nucleation. Furthermore, it is speculated that C-H scission is accelerated by bi- or trimolecular reactions using hydrogen as a carrier material. Promoting C-H scission suppresses undesirable C-C cleavage. Thus, pyrolysis of the feedstock to unsaturated species such as acetylenes and aromatic-containing intermediates can be improved, resulting in higher yields and uniform properties of carbon black.

[0017] The hydrogen gas and the oxygen-containing gas can be supplied to the combustion chamber via injection means or conduits. Preferably, the first fluid is an oxygen-containing gas and the second fluid is hydrogen, such that the oxygen-containing gas is supplied via the injection means and the hydrogen is supplied via the conduit. For example, the oxygen-containing gas (first fluid) can be provided to the combustion chamber by a lance pipe extending through the conduit, with the gap between the inner surface of the conduit and the outer surface of the lance pipe defining a passage for the second fluid, which is hydrogen.

[0018] The oxygen-containing gas is generally provided in an amount that does not result in an excess of oxygen relative to the amount of oxygen for complete combustion of the fuel. In other words, it is desirable to provide hydrogen in an amount that results in a molar excess of hydrogen relative to the amount of oxygen, such that the hydrogen (fuel) does not burn completely and is thereby present in the hot combustion mixture as well as the hot reaction mixture. The oxygen-containing gas is provided in an amount with a k value higher than 1, preferably 1.1-2000, 2-100, 3-50, 4-40, 5-30, and / or 6-20. The oxygen-containing gas is present in the combustion mixture with a k value higher than 1, preferably 1.1-2000, 2-100, 3-50, 4-40, 5-30, and / or 6-20. Here, the k value is defined by the ratio of the stoichiometric amount of O2 required for complete stoichiometric combustion of the fuel to the amount of O2 provided.

[0019] The molar ratio of hydrogen to oxygen-containing gas in the combustion mixture is from 100000 / 1 to greater than 1 / 1, such as from 10000 / 1 to greater than 1 / 1, from 5000 / 1 to 1.1 / 1, from 2000 / 1 to 2 / 1, from 30 / 1 to 2 / 1, from 25 / 1 to 2 / 1, from 20 / 1 to 2 / 1, or from 15 / 1 to 2 / 1. The molar ratio of oxygen-containing gas to hydrogen in the combustion mixture is from 0.000001 / 1 to less than 1 / 1, such as from 0.00001 / 1 to less than 1 / 1, from 0.0005 / 1 to 0.1 / 1, from 0.002 / 1 to 0.02 / 1, from 0.002 / 1 to 0.2 / 1, from 0.25 / 1 to 1 / 2, from 0.2 / 1 to 1 / 2, or from 0.15 / 1 to 1 / 1.1.

[0020] To achieve maximum efficiency, a molar ratio of 2 / 1 or greater is preferred. A molar ratio of 4 / 1 or 5 / 1 avoids oxidation flames. However, higher molar ratios are also particularly beneficial, since residual hydrogen is used as a carrier gas. Properties such as the surface properties of carbon black can be adjusted by adjusting the amount of oxygen-containing gas in the combustion mixture, and thus the amount of water produced.

[0021] Hydrogen can be supplied to the combustion chamber as a hydrogen gas mixture. The hydrogen gas mixture can have a purity of 85 mol% or more, preferably 90 mol% or more, more preferably 95 mol% or more, and most preferably 98 mol% or more. Purity refers to the amount of hydrogen in the hydrogen gas mixture supplied into the combustion chamber. The hydrogen gas mixture may contain impurities such as moisture, CO, CO2, small amounts of hydrocarbons such as methane, and additional non-hydrogen gases.

[0022] The oxygen-containing gas (O2-containing gas or O2-containing gas mixture) can be air, oxygen-enriched air, other oxygen-containing gases and / or pure oxygen (O2). Preferably, the oxygen-containing gas is oxygen-enriched air or O2, and most preferably the oxygen-containing gas is O2. The weight percent of oxygen present in the oxygen-containing gas should be 20-100 weight percent, preferably 50-99 weight percent, more preferably 60-95 weight percent, and most preferably 70-90 weight percent, where weight percent is based on the total weight of the oxygen-containing gas. A high oxygen concentration in the oxygen-containing gas is preferred in order to keep the content of low heat generating gases in the tail gas as low as possible.

[0023] Typically, the oxygen-containing gas is preheated to a temperature of 500-2400°C, preferably 500-2000°C, 500-1400°C, 500-1300°C, 500-1250°C, 500-1200°C, 500-1100°C, 600-900°C, or 750-950°C, before entering the combustion chamber and then mixed with the fuel, i.e. hydrogen, preferably the fuel is also preheated.

[0024] Typically, the hydrogen is preheated to a temperature of 500-2400°C, preferably 500-2000°C, 500-1400°C, 500-1300°C, 500-1250°C, 500-1200°C, 500-1100°C, 600-900°C, or 750-950°C, before entering the combustion chamber and then mixed with an oxygen-containing gas, preferably the oxygen-containing gas is also preheated.

[0025] Typically, the hydrogen and oxygen-containing gas are preheated to a temperature of 500-2400°C, preferably 500-2000°C, 500-1400°C, 500-1300°C, 500-1250°C, 500-1200°C, 500-1100°C, 600-900°C, or 750-950°C, and then mixed prior to entering the combustion chamber.

[0026] Preheating of the oxygen-containing gas and hydrogen can be done electrically or with a heat exchanger. Preheating of the hydrogen and / or oxygen-containing gas is particularly preferred since less energy needs to be generated from the combustion of hydrogen. Typically the temperature of combustion is between 1300°C and 3000°C, e.g., 1400-2200°C, 1300-1600°C, or 1300-2400°C, most preferably 1300-2400°C, and the temperature of the hot combustion mixture should be higher than the temperature of the preheated oxygen-containing gas and / or hydrogen. For example, if hydrogen and oxygen-containing gas are preheated to 1300°C, less oxygen-containing gas is needed to combust the hydrogen to raise the temperature to, e.g., 1600°C. The generated hot combustion mixture is then subjected to a reaction chamber, where a feedstock is injected into the hot combustion chamber. Injecting the feedstock into the hot combustion mixture cools the resulting hot reaction mixture to the desired temperature. Thus, the temperature of the hot reaction mixture can be adjusted by the amount of feedstock injected into the hot combustion mixture.

[0027] Additionally, another advantage of preheating and thus requiring less oxygen-containing gas is that the hot combustion and reaction mixtures contain less water (H2O). Water affects the surface properties of the carbon black produced. Thus, the amount of oxygen-containing gas, such as O2, in the combustion mixture can be used to control the amount of water in the hot combustion and / or reaction mixtures, which preferably controls the surface properties of the carbon black produced.

[0028] The hydrogen injected in step (a) or supplied in step (b) may be compressed hydrogen, and the absolute pressure of the compressed hydrogen is preferably 1.1 to 2,000 bar, for example 2 to 1,000 bar, 3 to 200 bar, or 4 to 100 bar. Compressed hydrogen increases the energy density. Also, according to the present invention, liquid hydrogen is introduced into the combustion chamber. The liquid hydrogen may be mixed with an oxygen-containing gas and combusted in the combustion chamber.

[0029] The method of the present invention may include an additional method step, which may include quenching the hot product mixture in a quench chamber of the reactor, preferably using a quench medium such as water, to obtain a quenched reaction mixture. However, a quench boiler or heat exchanger may also be used to quench the hot product mixture.

[0030] Additionally, (i) carbon black can be obtained from the high temperature reaction mixture and / or the quench reaction mixture and an exhaust gas mixture containing H2O, H2, CO and CO2. The exhaust gas mixture can also contain H2O, H2, and CO. In this case, the separation of CO2 and H2 can be omitted if a synthesis gas containing H2 and CO is desired, as described below.

[0031] The exhaust gas should be reprocessed before the hydrogen is separated. The CO present in the exhaust gas should be converted to CO2 (step j). The conversion can be carried out using the water-gas shift reaction, in which CO and water react to CO2 and H2. The water-gas shift reaction is well known and is used in the production of ammonia, hydrocarbons, methanol, and hydrogen. It is also often used in conjunction with the steam reforming of methane and other hydrocarbons.

[0032] Water present in the exhaust gas before or after step (k) can be condensed (step k) and thereby removed from the exhaust gas.

[0033] Hydrogen can be separated from the exhaust gas. The separation can be carried out using pressure swing adsorption techniques to separate H2 and CO2. In this way, the CO2 and H2 present in the exhaust gas mixture can be separated (step l). Said separation preferably occurs after steps (j) and (k).

[0034] The separated hydrogen can be fed as the first or second fluid to the combustion chamber of the reactor according to step (a) or (b) (step m). Preferably, hydrogen is provided as the second fluid. Recycling of hydrogen in the process according to the invention further improves the sustainability of carbon black production.

[0035] The separated hydrogen can also be collected and / or provided to a fuel cell to provide electrical energy that can be used to drive pumps or for pre-heating as described above to increase the sustainability of carbon black production.

[0036] Additionally, the shift or conversion of CO to CO2 can be omitted, resulting in a hydrogen / CO mixture, after the aforementioned separation, which can be recovered and used as synthesis gas. For example, the hydrogen / CO mixture can be used in a Fischer-Tropsch process to convert the mixture into aliphatic products. The aliphatic products can then be used as feedstock for carbon black production, increasing the sustainability of the process. The molar ratio of hydrogen to CO should be between 5 / 1 and 1.5 / 1, e.g., between 4 / 1 and 2 / 1.

[0037] In particular, the hot combustion gases preferably contain H2 and H2O. The hot combustion gases are generated after combustion of a combustion mixture containing an oxygen-containing gas and hydrogen. Small amounts of oxygen may be present in the hot combustion gases after combustion. However, it is desirable for the oxygen concentration to be as low as possible. Furthermore, it is desirable for the hot combustion gases to be free of nitrogen or to contain less than 1,000 ppm of nitrogen. If the molar content of oxygen is lower than the molar content of hydrogen in the combustion mixture, the hot combustion gases will contain hydrogen.

[0038] The hot combustion gas preferably contains 2 to 90% by weight, for example 5 to 60% by weight, 2 to 80% by weight, 10 to 70% by weight, 30 to 50% by weight, or 15 to 40% by weight of hydrogen based on the total weight of the hot combustion gas. The hot combustion gas may contain 10 to 95% by mole, for example 20 to 90% by mole, 30 to 80% by mole, 40 to 70% by mole, 20 to 60% by mole, or 25 to 50% by mole of hydrogen based on the total molar amount of the hot combustion gas.

[0039] Further, it is preferred that the hot combustion gases contain less than 5 mol %, preferably less than 2 mol %, more preferably less than 1 mol %, and most preferably less than 0.1 mol % of hydrocarbon fuel. It is particularly preferred that the hot combustion gases are free of hydrocarbon fuel.

[0040] Further, it is preferred that the combustion mixture comprises less than 5 mol %, preferably less than 2 mol %, more preferably less than 1 mol %, and most preferably less than 0.1 mol % of a hydrocarbon fuel. It is particularly preferred that the combustion mixture is free of hydrocarbon fuel.

[0041] Although hydrocarbon fuels may be present in the combustion mixture as impurities, it is desirable for the concentration of hydrocarbon fuels to be as low as possible.

[0042] The hydrocarbon fuel can be any hydrocarbon fuel for combustion of an oxygen-containing gas, for example, a liquid or gaseous hydrocarbon fuel, for example, aliphatic fuels such as methane, ethane, propane, butane, pentane, hexane, heptane, aromatic fuels, oil, ethylene, propene, acetylene, hexane, natural gas.

[0043] Additionally, the hot combustion gases and / or hot reaction mixture may contain H radicals and / or H+ ions derived from hydrogen. Hydrogen radicals and H+ ions accelerate C-H bond scission during pyrolysis of the feedstock material by bimolecular or trimolecular reactions, which can improve pyrolysis to unsaturated species such as acetylenes and aromatic-containing intermediates, and thus improve the yield of carbon black.

[0044] Thus, the hot reaction mixture may include H2O, H2, and the feedstock for carbon black. The hot product mixture may include H2O, H2, carbon black, CO, and CO2. The quench reaction mixture may include H2O, H2, carbon black, CO, and CO2. The carbon black may be separated from the hot product mixture or the quench reaction mixture. The remaining gas is considered to be tail gas.

[0045] The carbon black feedstock (i.e., the feedstock for carbon black) may be or include a non-aromatic feedstock, an aromatic feedstock, an aliphatic feedstock, an aliphatic oil, a sustainable feedstock, a renewable carbon black feedstock, and / or a bio-based feedstock. Thus, the carbon black feedstock is not limited to renewable carbon black feedstocks, sustainable feedstocks, and / or bio-based feedstocks.

[0046] Preferably, the aliphatic feedstock comprises a high content of aliphatic material (feedstock for carbon black derived from an aliphatic feedstock), such as 20-100% by weight, e.g. 40-100% by weight, 50-99% by weight, 60-95% by weight, or 80-90% by weight, based on the total weight of the feedstock for carbon black. Sustainable feedstocks, renewable carbon black feedstocks and / or bio-based feedstocks often comprise such high contents of aliphatic feedstock.

[0047] Sustainable carbon black feedstocks generally refer to feedstocks with a high content of aliphatic C-C bonds, preferably a low content of aromatic C-C bonds. Sustainable carbon black feedstocks can include aliphatic oils, renewable carbon black feedstocks, and biomass-based feedstocks. Biomass-based feedstocks, sustainable carbon black feedstocks and / or renewable carbon black feedstocks can be distinguished from fossil-based feedstocks by measuring the C14 content in the feedstock (radiocarbon dating). The relative amount of C14 atoms compared to C12 (C14 to C12 ratio) is lower in fossil-based feedstocks compared to biomass-based feedstocks.

[0048] Preferably, the carbon black raw material is a renewable carbon black raw material. The renewable carbon black raw material may comprise a plant-based raw material, preferably a non-edible plant-based raw material and / or a waste plant-based raw material. As used herein, the term "non-edible" refers to a material that is suitable for human consumption. The term "waste" refers to a material that is discarded or disposed of, e.g. after use, as unsuitable or no longer useful for its intended purpose. With regard to edible oils, i.e. cooking oils, used cooking oils are considered waste.

[0049] The renewable carbon black feedstock may comprise a solid component and / or a liquid component. Preferably, the renewable carbon black feedstock may comprise a liquid component.

[0050] The renewable carbon black feedstock may preferably comprise vegetable-based oil, more preferably non-edible vegetable-based oil and / or waste vegetable-based oil.

[0051] Renewable carbon black feedstocks according to the present invention may include waste wood including wood, grass, cellulose, hemicellulose, lignin, natural rubber and / or synthetic rubber obtained from renewable sources, black liquor, tall oil, rubber seed oil, tobacco seed oil, castor oil, pongamia oil, crambe oil, neem oil, apricot kernel oil, rice bran oil, cashew nut shell oil, Cyperus esculentus oil, cooking oil, distillation residue from biodiesel plants, or any mixture or combination thereof.

[0052] As used herein, the term "wood" refers to the porous and fibrous structural tissue found in the stems and roots of trees and other woody plants. Suitable examples of wood include, but are not limited to, pine, spruce, larch, juniper, ash, hornbeam, birch, alder, beech, oak, pin, horse chestnut, mulberry, or mixtures thereof. Suitable examples of grass include, but are not limited to, cereal grasses such as corn, wheat, rice, barley or millet; bamboo and grasses in natural grasslands, and species cultivated in lawns and pastures. Suitable examples of lignin include, but are not limited to, lignin and lignosulfonates removed by the Kraft process. The waste material containing natural rubber and / or synthetic rubber obtained from renewable raw materials may be tires, cable sheaths, tubes, conveyor belts, shoe soles, hoses, or mixtures thereof. Natural rubber may be derived from the rubber tree (Helvea brasiliensis), guayule, and dandelion. Synthetic rubbers may include styrene-butadiene rubber, such as emulsion-styrene-butadiene rubber (ESBR) and solution-styrene-butadiene rubber (SSBR), polybutadiene, polyisoprene, ethylene-propylene-diene rubber (EPDM), ethylene-propylene rubber (EPM), butyl rubber, halogenated butyl rubber, chlorinated polyethylene, chlorosulfonated polyethylene, acrylonitrile-butadiene rubber, hydrogenated acrylonitrile-butadiene rubber, polychloroprene, acrylate rubber, ethylene-vinyl acetate rubber, ethylene-acrylic rubber, epichlorohydrin rubber, silicone rubber, fluorosilicone rubber, fluorocarbon rubber, or any combination or mixture of the above. Synthetic rubbers, such as polybutadiene, may be produced from alcohol obtained by fermentation of plant biomass. A suitable preparation of alcohol obtained by fermentation and the preparation of polybutadiene from such alcohol is described in EP 2 868 697 A1.

[0053] As used herein, the term "cooking oil" refers to edible oils used for food preparation, such as frying, baking, and other types of cooking. According to the present invention, the cooking oil may include rice bran oil, rapeseed oil, linseed oil, palm oil, coconut oil, canola oil, soybean oil, sunflower oil, cottonseed oil, pine seed oil, olive oil, corn oil, grapeseed oil, safflower oil, acai palm oil, jambu oil, sesame oil, chia seed oil, hemp oil, perilla oil, peanut oil, stillingia oil, cashew nut oil, Brazil nut oil, macadamia nut oil, walnut oil, almond oil, hazelnut oil, beech nut oil, candlenut oil, chestnut oil, or any mixture or combination thereof. The cooking oil of the present invention may be used cooking oil. As used herein, the term "used cooking oil" refers to oil from a commercial or industrial food processing operation, such as a restaurant, that has been used for food preparation, such as cooking or frying.

[0054] The solid component may be selected from waste materials including, but not limited to, wood, grass, cellulose, hemicellulose, lignin, natural rubber and / or synthetic rubber obtained from renewable sources, or any mixture or combination thereof.

[0055] The liquid component may be selected from, but is not limited to, black liquor, tall oil, rubber seed oil, tobacco seed oil, castor oil, pongamia oil, crambe oil, neem oil, apricot kernel oil, rice bran oil, cashew nut shell oil, cyperus esculentus oil, cooking oil, distillation residue from biodiesel plants, or any mixture or combination of the above. Some oils may be solid at room temperature, e.g., at a temperature of 25°C, but may be liquid at elevated temperatures, e.g., at temperatures above 25°C, e.g., in the range of 25-100°C. As used herein, the term "black liquor" refers to a by-product from the Kraft process derived from the sulfate and soda process of producing cellulose pulp.

[0056] Non-edible plant-based feedstocks may include, but are not limited to, waste materials including wood, cellulose, hemicellulose, lignin, black liquor, tall oil, rubber seed oil, tobacco seed oil, castor oil, pongamia oil, crambe oil, neem oil, apricot kernel oil, rice bran oil, cashew nut shell oil, Cyperus esculentus oil, distillation residues from biodiesel plants, natural rubber and / or synthetic rubber obtained from renewable feedstocks, or any mixture or combination thereof.

[0057] Waste plant-based feedstocks may include, but are not limited to, waste materials including natural rubber and / or synthetic rubber derived from renewable sources, used cooking oil, or any mixture or combination thereof.

[0058] The carbon black raw material may include tall oil. The terms "tall oil" and "unrefined tall oil" may be used interchangeably throughout the specification unless otherwise specified. Tall oil is derived from chemical pulping of wood. Typically, tall oil is a mixture containing resin acids, fatty acids, sterols, alcohols and further alkyl hydrocarbon derivatives. Tall oil may be a natural unrefined product or a refined product. Refined tall oil may include tall oil fatty acids, tall oil fatty rosin, distilled tall oil and tall oil pitch. Tall oil may be distilled to obtain tall oil resin acids containing a resin acid content of more than 10% by weight. Tall oil may also be refined into tall oil fatty acids, where the resin acid content is typically less than 10% by weight. Suitable examples of tall oil include, but are not limited to, SYLFAT® products, SYLVATAL® products, SYLVABLEND® products and SYLVAROS® products (all available from Kraton Corporation, USA), as well as tall oil products such as unrefined tall oil and Tall Oil 1 (available from UCY Energy, Germany).

[0059] Carbon black feedstocks (i.e., raw materials for carbon black) may in particular comprise tall oil pitch. Tall oil pitch is obtained as a non-volatile residue from the refining of tall oil by distillation and may be mixed with the fore-runs of tall oil refining. The yield of tall oil pitch in the refining process may range from about 15 to 50% by weight, depending for example on the quality and composition of the tall oil. Tall oil pitch typically comprises neutrals, free acids including resin acids and fatty acids, fatty acid esters, bound and free sterols, and polymeric compounds. Furthermore, metals, metal cations, and inorganic-organic compounds including metal resinates and fatty acid salts can be found in tall oil pitch. Metal cations typically originate from wood and fertilizers. Suitable examples of tall oil pitches include, but are not limited to, SYLVABLEND® products, such as SYLVABLEND FA7002, SYLVABLEND PF40, SYLVABLEND PF60 and SYLVABLEND SF75 (all available from Kraton Corporation, USA), and Tall Oil 1, UCY-TOF40 and UCY-TOF60 (all available from UCY Energy, Germany).

[0060] According to the present invention, the carbon black feedstock (i.e., the feedstock for carbon black) can be a mixture of renewable carbon black feedstock and conventional carbon black feedstock. Conventional carbon black feedstocks can be aliphatic or aromatic, saturated or unsaturated hydrocarbons or mixtures thereof, coal tar distillates, residual oils produced during catalytic cracking of petroleum fractions, residual oils produced during olefin production via cracking of naphtha or gas oil, natural gas, or mixtures or combinations thereof. Thus, the carbon black feedstock is not limited to a specific feedstock material. The carbon black feedstock can be liquid, solid, as well as gaseous. It is preferred that the carbon black feedstock is liquid or gaseous. For example, the gaseous carbon black feedstock can be an aliphatic feedstock such as methane, ethane, acetylene, ethylene, ethane, propyne, propane propene, butadiene, butane, pentane, or mixtures thereof.

[0061] The carbon black raw material of the present invention (i.e., raw material for carbon black) can contain renewable carbon black raw material in an amount of 10% by weight or more, based on the total weight of the carbon black raw material. For example, the carbon black raw material according to the present invention can contain renewable carbon black raw material in an amount of 15% by weight or more, 20% by weight or more, 25% by weight or more, 30% by weight or more, 35% by weight or more, 40% by weight or more, 45% by weight or more, 50% by weight or more, 55% by weight or more, 60% by weight or more, 65% by weight or more, 70% by weight or more, 75% by weight or more, 80% by weight or more, 85% by weight or more, 90% by weight or more, or 95% by weight or more, based on the total weight of the carbon black raw material. The carbon black raw material can contain renewable carbon black raw material in an amount of 10% by weight or more, preferably 15% by weight or more, particularly preferably 25% by weight or more, more preferably 50% by weight or more, even more preferably 85% by weight or more, and most preferably 99% by weight or more, based on the total weight of the carbon black raw material. The carbon black raw material can consist of renewable carbon black raw material.

[0062] The carbon black feedstock (i.e., feedstock for carbon black) of the present invention can comprise tall oil pitch in an amount of 5% by weight or more, for example 10% by weight or more, 15% by weight or more, 20% by weight or more, 25% by weight or more, 25% by weight or more, 30% by weight or more, 35% by weight or more, 40% by weight or more, 45% by weight or more, 50% by weight or more, 55% by weight or more, 60% by weight or more, 65% by weight or more, 70% by weight or more, 75% by weight or more, 80% by weight or more, 85% by weight or more, 90% by weight or more, or 95% by weight or more, based on the total weight of the carbon black feedstock. The carbon black feedstock can comprise tall oil pitch in an amount of 10% by weight or more, preferably 15% by weight or more, particularly preferably 25% by weight or more, more preferably 50% by weight or more, even more preferably 85% by weight or more, and most preferably 95% by weight or more, based on the total weight of the carbon black feedstock. The carbon black feedstock can consist of tall oil pitch.

[0063] The renewable carbon black feedstock of the present invention may comprise tall oil pitch in an amount of 5% by weight or more, for example 10% by weight or more, 15% by weight or more, 20% by weight or more, 25% by weight or more, 30% by weight or more, 35% by weight or more, 40% by weight or more, 45% by weight or more, 50% by weight or more, 55% by weight or more, 60% by weight or more, 65% by weight or more, 70% by weight or more, 75% by weight or more, 80% by weight or more, 85% by weight or more, 90% by weight or more, or 95% by weight or more, based on the total weight of the renewable carbon black feedstock. The renewable carbon black feedstock may comprise tall oil pitch in an amount of 10% by weight or more, preferably 15% by weight or more, particularly preferably 25% by weight or more, more preferably 50% by weight or more, even more preferably 85% by weight or more, and most preferably 95% by weight or more, based on the total weight of the renewable carbon black feedstock. The renewable carbon black feedstock may consist of tall oil pitch.

[0064] The carbon black of the present invention can have a pMC (modern carbon content) of 1% or more, e.g., 2% or more, 5% or more, 7% or more, 10% or more, 12% or more, 15% or more, 17% or more, 20% or more, 22% or more, 25% or more, 27% or more, 30% or more, 32% or more, 35% or more, 37% or more, 40% or more, 42% or more, 45% or more, 47% or more, 50% or more, 52% or more, 55% or more, 57% or more, 60% or more, 62% or more, 65% or more, 67% or more, 70% or more, 72% or more, 75% or more, 77% or more, 80% or more, 82% or more, 85% or more, 87% or more, 90% or more, 92% or more, 95% or more, 97% or more, or 99% or more, as measured according to ASTM D6866-20, Method B (AMS). 14 C / 13The ratio of C is calculated and compared with the measurement made with oxalic acid II standard (NIST-4990C). The measured value (pMC) is corrected by d13C measured using an isotope ratio mass spectrometer (IRMS). The carbon black of the present invention can have a pMC (modern carbon content) of preferably 10% or more, particularly preferably 15% or more, more preferably 50% or more, even more preferably 85% or more, and most preferably 90% or more, as measured according to ASTM D6866-20, Method B (AMS). The carbon black of the present invention can have a pMC (modern carbon content) of 100% as measured according to ASTM D6866-20, Method B (AMS).

[0065] The temperature of the hot combustion gas into which the feedstock is injected in process step (f) and / or the temperature of the reaction in process step (g) may be between 700 and 2400°C, e.g. between 800 and 2200°C, 800 and 1400°C, 1500 and 2000°C, 1500 and 1800°C, 900 and 1300°C, 950 and 1400°C, or 1000 and 1200°C. For aliphatic feedstock materials, sustainable carbon black feedstocks, renewable carbon black feedstocks and / or bio-based feedstocks, a temperature range of 800 and 1400°C is preferred to prevent fast C-C bond cleavage. However, when hydrogen is used as a carrier material, the feedstock can be introduced at even higher temperatures. Aromatic carbon black feedstocks, such as fossil carbon black feedstocks, are stable enough that the aromatic C-C bonds are not thermally broken, so that they can be injected into the aforementioned gases even at 2000°C, preferably between 1300 and 2400°C, most preferably between 1450 and 2400°C.

[0066] Method step (f) may further comprise subjecting the hot reaction mixture to a plasma after injection of the raw material for carbon black, after raising the temperature of the raw material, preferably to a pyrolysis temperature, such as 700-2100 °C as defined above (and after evaporation of the raw material, if the raw material is liquid). The plasma treatment of the raw material material further increases the concentration of H radicals and / or H+ ions in the hot reaction mixture, thus increasing the yield of carbon black. It should be noted that the treatment of the hot reaction mixture is applied before the formation of carbon black, i.e., preferably before pyrolysis, nucleation, surface growth and agglomeration as described above. Thus, the plasma should be applied at a location within a reactor for producing carbon black, such as a furnace black reactor, where the raw material is injected into the hot combustion mixture, evaporated (if liquid) and heated to pyrolysis temperature. In other words, the plasma should be applied in the reactor chamber after the source material has reached a temperature up to the pyrolysis temperature, for example 700-2400°C, e.g. 800-2000°C, 800-1400°C, 1500-2000°C, 1500-1800°C, 900-1300°C, 950-1400°C, or 1000-1200°C (and even after evaporation if the source material is liquid) and especially before pyrolysis of the source material. It is clear that the gaseous source material does not need to be evaporated, since after injection into the reaction chamber the gaseous source material is already a gas.

[0067] A plasma torch can provide the plasma for the above-mentioned treatment. The design of the plasma torch is described in WO 1993 / 012633 A1. However, any means known in the art for generating plasma can be used. The plasma can be formed by a plasma carrier gas heated by an electric arc burning between electrodes. Plasma treatment is possible in a plasma zone at high temperatures of 3000°C to 20,000°C. The plasma carrier gas can be oxygen or hydrogen. Hydrogen as plasma carrier gas is particularly preferred.

[0068] Microwave plasma can also provide the plasma for the aforementioned treatment. For example, a microwave generator can be used that provides microwave radiation in the reaction chamber. Hydrogen already present in the high-temperature reaction mixture is then used as a plasma carrier material or as a gas to generate the plasma. Microwave radiation having 1-300 GHz can be used. Alternatively, the plasma can be generated using a high-frequency power source (RF generator). According to the present invention, a combustion mixture comprising an oxygen-containing gas and hydrogen and / or a high-temperature combustion mixture comprising hydrogen for carbon black production is used to produce carbon black. The oxygen-containing gas is preferably O2. Furthermore, the combustion mixture preferably comprises a molar excess of hydrogen relative to the oxygen present in the oxygen-containing gas. In other words, the molar ratio of hydrogen to oxygen should be greater than 1.

[0069] The hydrogen present in the reaction chamber of the carbon black reactor can be used to promote the pyrolysis reaction of the feedstock for carbon black. The hydrogen present in the reaction chamber of the carbon black reactor can be subjected to a plasma.

[0070] According to the present invention, hydrogen can be used as a carrier gas and / or a fuel for carbon black production. Hydrogen is preferably used as a carrier gas and a fuel for carbon black production. Hydrogen is used as a carrier gas when it is present in the combustion mixture in molar excess relative to oxygen. Thus, hydrogen should be present in the hot combustion gas and hot reaction mixture.

[0071] According to the present invention, the carbon black can be plasma black, gas black, channel black, thermal black, lamp black or furnace black, preferably furnace black.

[0072] The carbon black produced can have an oil absorption (OAN) of 80 mL / 100 g or less, measured according to ASTM D2414-19. For example, the carbon black can have an OAN of 70 mL / 100 g or less, e.g., 60 mL / 100 g or less, 50 mL / 100 g or less, 45 mL / 100 g or less, 40 mL / 100 g or less, or 37 mL / 100 g or less, measured according to ASTM D2414-19. The carbon black can have an OAN of 19 mL / 100 g or more, e.g., 23 mL / 100 g or more, or 25 mL / 100 g or more, measured according to ASTM D2414-19. The carbon black according to the present invention can have an OAN ranging between any of the recited lower and upper limits. The carbon black according to the present invention may have an OAN, measured according to ASTM D2414-19, in the range of 19 to 80 mL / 100 g, preferably 19 to 70 mL / 100 g, particularly preferably 23 to 60 mL / 100 g, more preferably 23 to 50 mL / 100 g, even more preferably 25 to 40 mL / 100 g, and most preferably 25 to 37 mL / 100 g.

[0073] The present invention is also directed to a reactor system for producing carbon black, preferably using the method according to any one of the above aspects, comprising a carbon black reactor comprising: (i) a combustion chamber for producing hot combustion gases by combustion of a combustion mixture comprising an oxygen-containing gas and hydrogen, (ii) a conduit for supplying a second fluid to the combustion chamber, (iii) an injection means for injecting a first fluid into the combustion chamber, and (iv) a reaction chamber subsequent to the combustion chamber, comprising a means for injecting a source of carbon black (I) into the hot combustion gases received from the combustion chamber to form carbon black, wherein the first fluid is an oxygen-containing gas and the second fluid is hydrogen, or the first fluid is hydrogen and the second fluid is an oxygen-containing gas. Preferably, the first fluid is an oxygen-containing gas and the second fluid is hydrogen. The carbon black reactor is preferably a furnace carbon black reactor.

[0074] The carbon black reactor may have a flow path along a central longitudinal axis of the reactor and may be a furnace black reactor. The reactor comprises, in the following order from upstream to downstream (flow direction), a combustion chamber, a reaction chamber, and optionally a quench chamber.

[0075] The reaction chamber is connected to the combustion chamber so that the hot combustion gases obtained in the combustion chamber can flow into the reaction chamber. The reaction chamber can be arranged along the central longitudinal axis of the reactor. The diameter of the reaction chamber can be larger than the diameter of the constriction of the combustion chamber so that the hot combustion gases can expand. The expansion is preferably dimensioned as a cylinder and communicates with the combustion chamber, preferably with the constriction of the combustion chamber.

[0076] The reaction chamber includes a means for injecting the carbon black feedstock into the hot combustion gases. The means for injecting the feedstock may comprise a plurality of injection nozzles preferably arranged circumferentially about the central longitudinal axis. The circumferential arrangement allows the carbon black feedstock to be intimately mixed with the hot combustion gases, further improving the uniformity of the carbon black.

[0077] The reactor system may further comprise a quench chamber downstream of the reaction chamber, and preferably includes means for injecting a quench medium into the quench chamber. The quench chamber may be a heat exchanger or a quench boiler.

[0078] The reactor system further comprises a filter unit for separating the carbon black from the hot reaction mixture and / or the quench reaction mixture to obtain a carbon black and tail gas mixture (or tail gas), the filter unit being in fluid communication with the quench chamber of the carbon black reactor.

[0079] The reactor system is intended to include a quenching chamber and a filter unit for separating the carbon black and the exhaust gas. The exhaust gas can then be reprocessed in different chambers or in one chamber to separate the remaining hydrogen from the exhaust gas, which can be re-fed to the reactor system as the first or second fluid.

[0080] Thus, the reactor system may further comprise: (A) a chamber for converting CO present in the exhaust gas mixture to CO2, preferably connected to a filter unit for separating carbon black and / or connected to a chamber for condensing H2O, (B) a chamber for condensing H2O present in the exhaust gas mixture, preferably connected to a filter unit for separating carbon black and / or connected to a chamber for converting CO, and / or (C) a chamber for separating CO2 and H2 present in the exhaust gas mixture, preferably connected to a chamber for condensing H2O and / or connected to a chamber for converting CO. Thus, the preferred order from upstream to downstream is: (A) a chamber for converting CO present in the exhaust gas mixture to CO2, (B) a chamber for condensing H2O, and (C) a chamber for separating CO2 and H2 present in the exhaust gas mixture. As mentioned above, when it is desired to obtain synthesis gas, (A) there is no chamber for converting the CO present in the flue gas mixture into CO2, and the separation chamber (C) separates H2 and the remaining CO2 from the flue gas, but the H2 portion also contains CO, so that a H2 / CO (H2 and H2O) mixture is obtained. When there is no CO2 present in the flue gas, i.e. when the flue gas contains CO, H2 and H2O, it is only necessary to filter the carbon black and condense the H2O, and the mixture obtained contains H2 and CO. In the above mentioned chambers or units, the separation, condensation and conversion can be achieved as described above.

[0081] The reactor system may further comprise a conduit (ii) for feeding the first fluid to the combustion chamber and a conduit for feeding H2 connected to a chamber for separating CO2 and H2, or an injection means for injecting the second fluid into the combustion chamber and a conduit for feeding H2 connected to a chamber for separating CO2 and H2. Thus, the hydrogen separated in said chamber may be re-fed to the reactor system to obtain a further improved and sustainable carbon black production.

[0082] The reactor chamber (iv) may also include a means (II) for generating plasma in the reaction chamber. The means for generating plasma may be a plasma torch, a microwave plasma generator, or a radio frequency generator as described above. The plasma carrier gas is preferably hydrogen so that the exhaust gas can be easily separated. The means for generating plasma (II) is arranged to inject the raw material for carbon black (I) downstream following said means. The means for generating plasma may be arranged in a circumferential direction with respect to the reaction chamber.

[0083] The injection means is preferably a lance pipe which extends through the conduit and forms a gap between an inner surface of the conduit and an outer surface of the lance pipe to define a passageway for the second fluid, the second fluid being preferably hydrogen and the first fluid being preferably an oxygen-containing gas.

[0084] The present invention will now be described with reference to the accompanying drawings, which do not limit the scope and area of ​​the present invention. The description provided is purely for the purposes of example and illustration. However, certain features illustrated in the drawings may be used to further limit the scope of the present invention and the claims.

[0085] Figure 1 shows a furnace carbon black reactor (100) for the production of carbon black. The furnace carbon black reactor (100) is part of a reactor system according to the invention, and the process according to the invention can be carried out in said furnace carbon black reactor (100) of the reactor system.

[0086] The furnace carbon black reactor (100) comprises a combustion chamber (120), a reaction chamber (130) and a quench chamber (140). Furthermore, a tubular conduit (110) is connected to the combustion chamber (120). These components are arranged along the central longitudinal axis (101) of the reactor and form a flow path. Arrow (102) indicates the flow direction of hydrogen (second fluid) which is fed to the combustion chamber (120) through the tubular conduit (110). In this reactor (100), the injection means is a lance pipe (111) provided inside the tubular conduit (110). The lance pipe (111) is arranged along the central longitudinal axis (101) of the reactor. Arrow (103) indicates the flow direction of an oxygen-containing gas (first fluid), which is preferably oxygen. However, oxygen injection means arranged circumferentially relative to the central longitudinal axis (101) of the reactor or tubular conduit (110) are also in accordance with the invention.

[0087] Hydrogen and an oxygen-containing gas are mixed and the fuel, i.e. hydrogen, is burned in the combustion chamber (120). The resulting hot combustion mixture, which typically contains H2 as a carrier gas, is then transferred into the reaction chamber (130). The reaction chamber (130) contains a number of feedstock injection means (131) for injecting the carbon black feedstock (132) (i.e. hydrocarbon feedstock). Additionally, a means for generating plasma (133) is present downstream of the feedstock injection means (131) in the reactor chamber (130). The means for generating plasma (133) should be located close to the feedstock injection means (131) so that the feedstock is heated at most to the pyrolysis temperature (and vaporized if the feedstock is in liquid form) and is not substantially pyrolyzed.

[0088] The quench chamber (140) is positioned after the reaction chamber (130). The quench chamber (140) includes a number of injection nozzles (134) for injecting a quench medium (135), such as water. As mentioned above, a heat exchanger or quench boiler may also be used.

[0089] Thus, the diagram shows a carbon black reactor comprising the following chambers from upstream to downstream (flow direction): a combustion chamber (120), a reaction chamber (130), and a quench chamber (140).

[0090] The produced carbon black and tail gases can then be subjected to a filter unit, and the hydrogen can be separated and re-fed to the tubular conduit (110) (not shown). The hydrogen can be recovered or the hydrogen / CO mixture can be used as synthesis gas.

[0091] It will be understood that various modifications can be made and many changes can be made in the preferred embodiment without departing from the principles of the invention.

[0092] Aspects of the invention 1. A method for producing carbon black, preferably carried out in a reactor system according to any one of embodiments 17 to 24, preferably in use according to any one of embodiments 26 to 31, comprising the steps of: (a) injecting a first fluid into a combustion chamber of a reactor using an injection means; (b) supplying a second fluid into the combustion chamber through a conduit; (c) mixing the second fluid with the first fluid to obtain a combustion mixture; (d) combusting a combustion mixture in a combustion chamber to produce hot combustion gases; (e) receiving the hot combustion gases in a reaction chamber of the reactor after the combustion chamber; (f) injecting a carbon black feedstock (or a carbon black feedstock) into the hot combustion gases received from the combustion chamber to obtain a hot reaction mixture containing the carbon black feedstock (or the carbon black feedstock); and (g) reacting the hot reaction mixture in the reaction chamber to obtain a hot product mixture comprising carbon black; Manufacturing methods including: Here, the first fluid is an oxygen-containing gas and the second fluid is hydrogen, or the first fluid is hydrogen and the second fluid is an oxygen-containing gas. 2. 2. The method of embodiment 1, wherein the first fluid is an oxygen-containing gas, in particular O2, and the second fluid is hydrogen. 3. 3. The method according to aspect 1 or 2, wherein the oxygen-containing gas is O2 and / or the weight percentage of oxygen present in the oxygen-containing gas is 20-100 weight%, preferably 50-99 weight%, more preferably 60-95 weight%, and most preferably 70-90 weight%, based on the total weight of the oxygen-containing gas. 4. The method according to any one of aspects 1 to 3, wherein the hydrogen injected in step (a) or supplied in step (b) is compressed hydrogen, and the absolute pressure of the compressed hydrogen is preferably from 1.1 to 2,000 bar, such as from 2 to 1,000 bar, from 3 to 200 bar, or from 4 to 100 bar. 5. (h) quenching the hot product mixture in a quench chamber of the reactor, preferably using a quenching medium such as water, to obtain a quenched reaction mixture; (i) obtaining carbon black from a hot reaction mixture and / or a quenched reaction mixture and an off-gas mixture comprising HO, H, CO and CO; (j) converting CO contained in the exhaust gas mixture into CO2; (k) condensing H2O present in the exhaust gas mixture; (l) Separating the CO2 and H2 present in the exhaust gas mixture; and / or (m) providing the separated H2 as a first or second fluid to a combustion chamber of the reactor in step (a) or (b); The method according to any one of aspects 1 to 4, further comprising: 6. The method according to any one of aspects 1 to 5, wherein the separated H2 is supplied to a fuel cell that supplies electrical energy. 7. The method according to any one of aspects 1 to 6, wherein CO is not converted to CO2 and during separation of the tail gas mixture a hydrogen / CO mixture is obtained, preferably with a hydrogen to CO molar ratio of 5 / 1 to 1.5 / 1, such as 4 / 1 to 2 / 1. 8. (i) The hot combustion gases contain H2O and H2; (ii) the high temperature reaction mixture comprises H2O, H2, and a raw material for carbon black; (iii) the high temperature product mixture comprises H2O, H2, carbon black, CO and CO2; and / or (iv) the quench reaction mixture comprises HO, H, carbon black, CO and CO; The method according to any one of aspects 1 to 7. 9. Aspects 9. The method of any one of aspects 1 to 8, wherein the carbon black feedstock is or comprises a non-aromatic feedstock, an aromatic feedstock, an aliphatic feedstock, a sustainable carbon black feedstock, a renewable carbon black feedstock, and / or a bio-based feedstock. 10. 10. The method of any one of aspects 1 to 9, wherein the temperature at which the carbon black feedstock is injected into the hot combustion gas in method step (f) and / or the temperature of the reaction in method step (g) is from 700 to 2400°C, e.g., from 800 to 2000°C, from 800 to 1400°C, from 1500 to 2000°C, from 1500 to 1800°C, from 900 to 1300°C, from 950 to 1400°C, or from 1000 to 1200°C. 11. The method according to any one of aspects 1 to 10, wherein method step (f) further comprises subjecting the hot reaction mixture to a plasma after injection of the raw material for the carbon black, preferably after raising the temperature of the raw material to a pyrolysis temperature of 700-2100°C, e.g., 800-1400°C and / or 1400-2000°C. 12. 12. The method of any one of aspects 1-11, wherein the high temperature reaction mixture comprises H radicals and / or H+ ions derived from hydrogen, preferably generated by a plasma. 13. 13. The method of any one of aspects 1-12, wherein the hot combustion gas comprises 2 to 90 wt.%, e.g., 5 to 60 wt.%, 2 to 80 wt.%, 10 to 70 wt.%, 30 to 50 wt.%, or 15 to 40 wt.% hydrogen, based on a total weight of the hot combustion gas. 14. The method of any one of aspects 1-13, wherein the molar ratio of hydrogen to oxygen-containing gas in the combustion mixture is from 100000 / 1 to greater than 1 / 1, e.g., from 10000 / 1 to greater than 1 / 1, from 5000 / 1 to 1.1 / 1, from 2000 / 1 to 2 / 1, from 30 / 1 to 2 / 1, from 25 / 1 to 2 / 1, from 20 / 1 to 2 / 1, or from 15 / 1 to 2 / 1. 15. 15. The method of any one of aspects 1-14, wherein a first fluid, such as an oxygen-containing gas, is injected into the combustion chamber by a lance pipe extending through the conduit, a gap between an inner surface of the conduit and an outer surface of the lance pipe defining a passage for a second fluid, such as hydrogen. 16. (i) the hydrogen is preheated to a temperature of 500-2400°C, preferably 500-2000°C, 500-1400°C, 500-1300°C, 500-1250°C, 500-1200°C, 500-1100°C, 600-900°C, or 750-950°C, before entering the combustion chamber; and / or (ii) the oxygen-containing gas is preheated to a temperature of 500-2400°C, preferably 500-2000°C, 500-1400°C, 500-1300°C, 500-1250°C, 500-1200°C, 500-1100°C, 600-900°C, or 750-950°C, before entering the combustion chamber; The method according to any one of aspects 1 to 15. 17. A reactor system for producing carbon black, preferably using the method according to any one of aspects 1 to 16, (i) a combustion chamber for producing hot combustion gases by combustion of a combustion mixture including an oxygen-containing gas and hydrogen; (ii) a conduit supplying a second fluid to the combustion chamber; (iii) an injection means for injecting a first fluid into the combustion chamber; and (iv) a reaction chamber following the combustion chamber, which includes a means for injecting a feedstock for carbon black (I) into the hot combustion gases received from the combustion chamber to form carbon black; A reactor system comprising a carbon black reactor comprising: Here, the first fluid is an oxygen-containing gas and the second fluid is hydrogen, or the first fluid is hydrogen and the second fluid is an oxygen-containing gas. 18. 18. The reactor system of embodiment 17, wherein the first fluid is an oxygen-containing gas, preferably the oxygen-containing gas is O2, and the second fluid is hydrogen. 19. 19. The reactor system of embodiment 17 or 18, wherein the reactor further comprises a quench chamber downstream following the reaction chamber and preferably comprises means for injecting a quench medium into the quench chamber. 20. 20. The reactor system of any one of aspects 17-19, wherein the reactor system further comprises a filter unit for separating the carbon black from the high temperature reaction mixture and / or the quench reaction mixture to obtain a carbon black and tail gas mixture, the filter unit being in fluid communication with the quench chamber of the carbon black reactor. twenty one. (A) a chamber for converting the CO present in the exhaust gas mixture into CO2, preferably connected to a filter unit for separating carbon black and / or to a chamber for condensing HO; (B) a chamber for condensing the HO present in the exhaust gas mixture, preferably connected to a filter unit for separating carbon black and / or connected to a chamber for converting CO, and / or (C) a chamber for separating the CO2 and H2 present in the exhaust gas mixture, preferably connected to a chamber for condensing H2O and / or connected to a chamber for converting CO; 21. The reactor system of any one of aspects 17-20, comprising: twenty two. The reactor system according to embodiment 21, further comprising a conduit (ii) for supplying the first fluid to the combustion chamber and a conduit for supplying H2 connected to the chamber for separating CO2 and H2, or an injection means (iii) for injecting the second fluid into the combustion chamber and a conduit for supplying H2 connected to the chamber for separating CO2 and H2. twenty three. 23. The reactor system according to any one of aspects 17 to 22, wherein the reactor chamber (iv) comprises a means (II) for generating a plasma in the reaction chamber, the means (II) for generating a plasma injecting a raw material for the carbon black (I) downstream therefrom. twenty four. 24. The reactor system of any one of aspects 17-23, wherein the injection means is a lance pipe extending within said conduit for the first fluid, a gap between an inner surface of the conduit and an outer surface of the lance pipe defining a passage for the second fluid. twenty five. 27. A carbon black produced according to the method of any one of embodiments 1 to 16 and / or using the reactor system of any one of embodiments 17 to 24. 26. Use of a combustion mixture comprising an oxygen-containing gas and hydrogen and / or a high-temperature combustion mixture comprising hydrogen for the production of carbon black, preferably in the method according to any one of embodiments 1 to 16, and / or with the reactor system according to any one of embodiments 17 to 24. 27. 27. The use of embodiment 26, wherein hydrogen present in the reaction chamber of the carbon black reactor is used to promote the pyrolysis reaction of the feedstock for carbon black. 28. 28. The use according to embodiment 26 or 27, wherein the hydrogen present in the reaction chamber of the carbon black reactor is subjected to a plasma. 29. 29. The use of any one of aspects 26 to 28, wherein the amount of oxygen-containing gas, such as O2, in the combustion mixture is used to control the amount of water in the high temperature combustion mixture and / or high temperature reaction mixture, thereby preferably controlling the surface properties of the produced carbon black. 30. Use of hydrogen as a carrier gas and / or fuel for the production of carbon black, preferably in the method according to any one of embodiments 1 to 16, and / or with the reactor system according to any one of embodiments 17 to 24. 31. The use according to embodiment 30, wherein hydrogen is used as a carrier gas or as a carrier gas and a fuel. 32. 17. The method of any one of aspects 1-16, wherein an oxygen-containing gas is present in the combustion mixture and / or is provided in an amount having a k value higher than 1, preferably 1.1-2000, 2-100, 3-50, 4-40, 5-30, and / or 6-20. 33. 25. The reactor system of any one of aspects 17-24, wherein the oxygen-containing gas is present in the combustion mixture or in the combustion chamber in an amount having a k value higher than 1, preferably 1.1-2000, 2-100, 3-50, 4-40, 5-30, and / or 6-20. 34. 25. The reactor system according to any one of aspects 17-24, wherein the oxygen-containing gas is provided in an amount having a k value higher than 1, preferably from 1.1 to 2000, from 2 to 100, from 3 to 50, from 4 to 40, from 5 to 30, and / or from 6 to 20. [Explanation of symbols]

[0093] 100 Carbon Black Reactor 110 Tubular conduit 111 Lance Pipe 120 Combustion chamber 130 Reaction Chamber 132 Carbon black raw materials 135 Quenching medium 140 Quenching chamber

Claims

1. A method for manufacturing carbon black, (a) Injecting a first fluid into the combustion chamber of the reactor using an injection means, (b) Supplying a second fluid into the combustion chamber through a conduit, (c) Mixing the second fluid with the first fluid to obtain a combustion mixture, (d) Combusting a combustion mixture in a combustion chamber to generate high-temperature combustion gas, (e) After the combustion chamber, high-temperature combustion gases are received in the reaction chamber of the reactor. (f) Injecting raw materials for carbon black into the high-temperature combustion gas received from the combustion chamber to obtain a high-temperature reaction mixture containing the raw materials for carbon black, and (g) Reacting a high-temperature reaction mixture in a reaction chamber to obtain a high-temperature product mixture containing carbon black. Manufacturing methods including: Here, the first fluid is an oxygen-containing gas and the second fluid is hydrogen, or the first fluid is hydrogen and the second fluid is an oxygen-containing gas, and the oxygen-containing gas is supplied in an amount such that the k value is greater than 1.

2. The first fluid is an oxygen-containing gas, especially O ２ The second fluid is hydrogen, and / or the oxygen-containing gas is O ２ The method according to claim 1.

3. (h) Rapidly cool the high-temperature product mixture in the rapid cooling chamber of the reactor to obtain a rapidly cooled reaction mixture. (i) Obtain carbon black from the high-temperature reaction mixture and / or the quenched reaction mixture, H ２ O, H ２ CO and CO ２ To obtain an exhaust gas mixture containing, (j) CO contained in the exhaust gas mixture ２ Converting to (k) H present in the exhaust gas mixture ２ Condensing O, (l) Separating CO ２ and H ２ present in the exhaust gas mixture, and / or (m) Separated H ２ This is provided as a first or second fluid to the combustion chamber of the reactor in step (a) or (b), The method according to claim 1 or 2, further comprising:

4. (i) High-temperature combustion gas is H ２ O and H ２ Includes, (ii) The high-temperature reaction mixture is H ２ O, H ２ and includes raw materials for carbon black, (iii) The high-temperature product mixture is H ２ O, H ２ , carbon black, CO and CO ２ including and / or (iv) The rapidly cooled reaction mixture is H ２ O, H ２ , carbon black, CO and CO ２ including, The method according to claim 1 or 2.

5. The method according to claim 1 or 2, further comprising step (f) of subjecting a high-temperature reaction mixture to a plasma after injecting the raw materials for carbon black.

6. The method according to claim 1 or 2, wherein the high-temperature reaction mixture comprises H radicals and / or H+ ions derived from hydrogen.

7. A reactor system for the carbon black production method according to Claim 1, (i) A combustion chamber that generates high-temperature combustion gas by combustion of a combustion mixture containing oxygen and hydrogen, (ii) A conduit for supplying a second fluid to the combustion chamber, (iii) an injection means for injecting a first fluid into a combustion chamber, and (iv) A reaction chamber following a combustion chamber, which includes means for injecting raw materials for carbon black (I) into high-temperature combustion gas received from a combustion chamber to form carbon black, Reactor system including a carbon black reactor: Here, the first fluid is an oxygen-containing gas and the second fluid is hydrogen, or the first fluid is hydrogen and the second fluid is an oxygen-containing gas.

8. The reactor system according to claim 7, wherein the first fluid is an oxygen-containing gas and the second fluid is hydrogen.

9. The reactor system according to claim 7 or 8, further comprising a filter unit for separating carbon black from a high-temperature reaction mixture and / or a quenched reaction mixture to obtain a carbon black and exhaust gas mixture, wherein the filter unit is fluidly connected to the quenching chamber of the carbon black reactor.

10. (A) CO present in the exhaust gas mixture ２ Chamber for converting, (B) H present in the exhaust gas mixture ２ A chamber for condensing O, and / or (C) CO present in the exhaust gas mixture ２ and H ２ Chamber for separating, A reactor system according to claim 7 or 8, including the following:

11. The reactor system further includes a conduit (ii) and CO for supplying the first fluid to the combustion chamber. ２ and H ２ H ２ A conduit for supplying CO, or an injection means (iii) for injecting a second fluid into the combustion chamber and CO ２ and H ２ H ２ The reactor system according to claim 10, further comprising a conduit for supplying [the substance].

12. The reactor system according to claim 7 or 8, wherein the reactor chamber (iv) includes means (II) for generating plasma within the reaction chamber, and the means (II) for generating plasma injects raw materials for carbon black (I) downstream thereafter.

13. Use of a combustion mixture containing oxygen-containing gas and hydrogen for the carbon black production method according to Claim 1, wherein the oxygen-containing gas is supplied in an amount such that the k value is greater than 1.

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