Method for producing carbon black from low yield feedstocks utilizing plasma or electrical heating processes and products produced therefrom

Abstract

Methods for producing carbon black from low yield carbon black feedstocks using a process that includes using electrical energy to form carbon black from the carbon black feedstock are described. Carbon black produced from these carbon black feedstocks is further described. Advantages achieved by the methods are further described.

Description

[Technical field]

[0001] The present invention relates to methods of producing carbon black made from alternative carbon black production feedstocks, which may often include gaseous and / or low yield feedstocks. More specifically, the present invention relates to methods of producing carbon black utilizing plasma or electrical heating processes. The present invention further relates to carbon black formed from alternative carbon black production feedstocks, including gaseous and / or low yield carbon black feedstocks.

[0002] Carbon black has been used to modify the mechanical, electrical, and optical properties of compositions. Carbon black and other fillers have been utilized as pigments, fillers, and / or reinforcing agents in the formulation 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 various performance properties of these compositions. An important application of elastomeric compositions is in the manufacture of tires, where additional ingredients are often added to impart specific properties to the final product or its components. Carbon black has been used to modify the functional properties, electrical conductivity, rheology, surface properties, viscosity, appearance, and other properties in elastomeric compositions and other types of compositions.

[0003] The most common conventional process for the industrial production of carbon black is the furnace process. In this method, a first liquid carbon-containing feedstock, such as decant oil, is injected into a fuel-lean hot combustion gas stream or gas stream undergoing combustion. A portion of the feedstock pyrolyzes to produce carbon black and by-products (mainly hydrogen). The remainder oxidizes to produce CO, CO2, and H2O. Conventional or traditional feedstocks are decant oil, slurry oil, coker oil, coal tar derivatives, or heavy liquid residues from the ethylene cracker process. All of these carbon black feedstocks are heavy (specific gravity greater than 1.02), have atomic H:C ratios up to 1.23, are rich in aromatics (Bureau of Mines Correlation Index (BMCI) 100 or greater), and are liquid at room temperature and pressure (e.g., 25°C at 1 atm). All of them are generally derived from fossil fuels.

[0004] Electrically heated carbon black processes are an alternative to furnace carbon black processes, such as those described in U.S. Pat. No. 1,536,612. In these processes, electricity is used to provide some or all of the energy needed to drive the fast, high temperature pyrolysis of the carbon-containing feedstock into carbon black particles and by-product gases. This is in contrast to furnace processes, where partial combustion of fuel provides this energy. Combustion gases are either generated within or mixed directly with the carbon-containing feedstock to drive the pyrolysis into carbon black. Although furnace processes are central to the commercial production of carbon black, electrically driven processes offer one or more potential advantages over furnace processes.

[0005] Electrically driven processes can use renewable electricity instead of fossil fuel combustion, which substantially reduces greenhouse gas emissions compared to furnace processes. Electrically driven processes can provide a higher yield of carbon black per unit of feedstock consumed, saving operational costs compared to furnace processes. The use of electrical energy to provide much or all of the energy needed to drive pyrolysis can allow for further control over the gas phase chemical environment in which the carbon black forms. Because the energy does not have to come entirely from combustion, the chemical environment during particle formation can be more reducing (as opposed to oxidizing). This provides a further method for controlling the final surface chemistry of the particles.

[0006] Electrically heated carbon black processes, such as those described in U.S. Patent No. 10,100,200, tend to use natural gas, ethane, or similar gas-phase carbon-containing feedstocks as the feedstock for carbon black production. A drawback of these gas-phase feedstocks is that they tend to produce very low structure for a given surface area. This structure can often be too low to meet the requirements of ASTM grades for rubber toughening.

[0007] A further drawback of the electrically heated carbon black process is the use of a carrier gas. This is done because direct exposure of the carbon-containing feedstock to high temperatures, intensely heated surfaces such as those produced by electrodes, can result in rapid coke formation and serious operability problems. Furthermore, many electrode materials can be corroded in service by hot hydrocarbon gases.

[0008] The use of a carrier gas such as hydrogen or argon solves these two problems, but creates another problem: the volume of the carrier gas must be large compared to the volume of the feedstock. Because high temperatures are required to generate adequate surface area in aerosol-based carbon black processes, this means that as the required product surface area increases, more and more carrier gas must be used relative to the amount of feedstock. The increased carrier gas volume significantly increases capital costs.

[0009] It is economically useful and environmentally beneficial to use gaseous, renewable, recycled, and / or sustainable low-yield feedstocks in existing carbon black processes. These feedstocks do not necessarily have to be fossil fuel-based. Examples of these include ethylene, which can be produced from ethane cracking or bioethanol. Another example is natural gas, which may be fossil-based or produced from landfills or decay of organic matter. Further examples include vegetable oil, recycled tires, plastics, oils derived from pyrolysis of municipal waste or biomass, or natural gas produced from landfills.

[0010] Unfortunately, these low yield carbon black feedstocks generally result in lower yields, lower surface areas, and / or lower structure in the carbon black process compared to traditionally used carbon black feedstocks. The performance of these feedstocks in electrically heated carbon black processes can be so poor that it may not be possible to produce the structure required for most ASTM grades with them. The maximum structure achievable for a given surface area for a feedstock helps define the grade capability of the feedstock.

[0011] Therefore, there is a need in the industry to provide a solution that can utilize electrically heated carbon black processes that can significantly increase the structure of the carbon black produced.

[0012] There is also a need in the industry to provide a solution to reduce capital costs by achieving a given surface area at a lower reaction temperature for electrically heated carbon black processes.

[0013] Additionally, there is a need in the industry to provide a solution that can use (or enable the use of) varying amounts of low yield carbon black forming feedstocks in existing electrically heated carbon black processes, and yet produce carbon blacks that are comparable to carbon blacks formed from traditional carbon black feedstocks (e.g., produce carbon blacks with acceptable yields and / or high surface area and / or high structure). Using an electrically heated carbon black process to use these low yield feedstocks instead of developing, designing, and building new processes to use these low yield feedstocks saves significant capital and development resources. All patents and publications mentioned throughout are incorporated herein by reference in their entirety. Summary of the Invention

[0014] A feature of the present invention is to provide a method for preparing or producing carbon black from feedstocks, including low yield carbon black feedstock(s).

[0015] A further feature of the present invention is to provide a method for preparing or producing carbon black from a feedstock that includes a gaseous carbon black feedstock.

[0016] Yet another feature of the present invention is to provide a method for preparing or producing carbon black utilizing an electrically heated carbon black process to significantly increase the structure of the carbon black produced.

[0017] It is also a feature of the present invention to provide a method for preparing or manufacturing carbon black utilizing an electrically heated carbon black process, thereby reducing capital costs by achieving a given surface area at a lower reaction temperature in the electrically heated carbon black process.

[0018] A further feature of the present invention is to provide carbon blacks made from feedstocks, including low yield carbon black feedstocks.

[0019] Another feature of the present invention is to provide a carbon black produced from a feedstock that includes a gaseous carbon black feedstock.

[0020] A further feature is to provide a process utilizing carbon black feedstock, wherein at least a portion or more of the total amount of feedstock is a low yield carbon black feedstock.

[0021] A further feature is to provide a method for producing carbon black from a low yield carbon black feedstock, such that the resulting carbon black has an acceptable (e.g., good) yield, an acceptable (e.g., high) surface area, and / or an acceptable structure (e.g., high structure).

[0022] To achieve these and other advantages, and in accordance with the purpose of the present invention, as embodied and broadly described herein, the present invention relates in part to a method for producing carbon black, the method including 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 includes at least one first carbon black feedstock and at least one low-yield carbon black feedstock. In one method of the present invention, the first carbon black feedstock is first contacted with a heated carrier gas formed by electrically heating the carrier gas to form a reaction stream, and then the low-yield carbon black feedstock is combined downstream with the existing reaction stream to form the carbon black. The method further includes recovering the carbon black in the reaction stream. In the method, the at least one low-yield carbon black feedstock preferably constitutes at least 10% by weight of the total feedstock and no more than 90% by weight of the total feedstock (based on total weight).

[0023] The present invention further relates, in part, to a further method for producing carbon black, the method comprising 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 one first carbon black feedstock and at least one low-yield carbon black feedstock. In this process of the present invention, the first carbon black feedstock and the low-yield carbon black feedstock are contacted with a heated carrier gas formed by electrically heating the carrier gas to form a reaction stream and form the carbon black. The at least one first carbon black feedstock and the at least one low-yield carbon black feedstock may be in the form of a blend or may be introduced separately at the same or about the same location. The method further comprises recovering the carbon black in 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 no more than 90% by weight of the total feedstock (based on total weight).

[0024] The invention further relates, in part, to a carbon black(s) wherein at least 10% by weight of the raw materials used to form the carbon black are at least one low yield carbon black raw material, and at least 10% by weight of the raw materials used to form the carbon black are at least one carbon black raw material.

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

[0026] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are intended to further explain the scope of the invention as claimed.

[0027] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate various features of the present invention and, together with the detailed description, serve to explain the principles of the invention. [Brief description of the drawings]

[0028] [Figure 1] 1 is a graph showing the atomic H:C (atom hydrogen to carbon atom) ratio for conventional carbon black feedstocks compared to low yield feedstocks used in part in the present invention.

[0029] [Diagram 2] 1 is a graph showing the specific gravity of conventional carbon black feedstocks compared to low yield feedstocks used in part in the present invention.

[0030] [Diagram 3] 1 is a graph showing BMCI values ​​for conventional feedstocks compared to low yield feedstocks used in part in the present invention.

[0031] [Figure 4] FIG. 1 is a cross-sectional view of an example of a reactor suitable for preparing the carbon black of the present invention.

[0032] [Diagram 5] FIG. 2 is a cross-sectional view of another example of a reactor suitable for preparing the carbon black of the present invention.

[0033] [Figure 6] FIG. 2 is a cross-sectional view of a further example of a reactor suitable for preparing the carbon black of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0034] The present invention relates to a method for producing carbon black utilizing a low yield carbon black feedstock as defined and described herein and utilizing an electrically heated carbon black process. The present invention further relates to carbon black produced from one or more of these processes. In the present process, a portion of the total carbon black feedstock utilized can be one or more low yield carbon black feedstocks. Not only can the present process use low to large amounts of low yield carbon black feedstock, but there is no sacrifice in terms of the quality of the carbon black produced. Thus, the present process utilizes carbon black feedstocks that are more desirable to use for environmental and / or other reasons, and yet produces carbon black that is comparable to carbon black produced using conventional carbon black feedstocks used in furnace carbon black processes and / or conventional plasma processes.

[0035] The method for producing carbon black 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 an existing reaction stream to form carbon black, and recovering the carbon black in the reaction stream. In the method, preferably, the at least one low yield carbon black feedstock comprises at least 10% by weight of the total feedstock, more preferably at least 25% by weight of the total feedstock or at least 50% by weight 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.

[0036] Another method of the present invention comprises, consists essentially of, consists of, or includes combining a carbon black feedstock comprising, consisting essentially of, consisting of, or including 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, forming the carbon black, and recovering the carbon black in the reaction stream. The carbon black feedstock can be introduced as a blend, or multiple separate carbon black feedstocks can be introduced (e.g., at the same location or about the same location) and combined with the electrically heated gas stream. In this method, preferably, the at least one low yield carbon black feedstock comprises at least 10% by weight of the total feedstock, more preferably at least 25% by weight of the total feedstock or at least 50% by weight of the total feedstock, and the first carbon black feedstock comprises at least 10% by weight of the total feedstock.

[0037] For purposes of this invention, a "low yield carbon black feedstock" is a carbon black feedstock that has at least one of the following characteristics: 1) Bureau of Mines Correlation Index (BMCI) less than 100 (providing an indication of low aromatic content for liquid feeds) (e.g., BMCI less than 99, less than 95, less than 90, less than 85, less than 80, less than 75, less than 70, e.g., BMCI of 50-99, or 60-99, or 70-99, or 50-95, or 50-90), and / or 2) a carbon-containing material that is gaseous at room temperature (e.g., 25°C) and room pressure (1 atm); and / or 3) An atomic H:C ratio of more than 1.23 (e.g., 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, or 1.50 or more, e.g., 1.235 to 1.5, or 1.235 to 1.45, or 1.235 to 1.4, or 1. 235-1.35, or 1.235-1.3, or 1.235-1.29, or 1.235-1.28, or 1.235-1.27, or 1.24-1.5, or 1.25-1.5, or 1.26-1.5, or 1.27-1.5, or 1.28-1.5, or 1.29-1.5, or 1.3-1.5), and / or 4) Specific gravity of up to 1.02 (e.g., up to 1.015, up to 1.01, up to 1.005, up to 1.01, up to 1.00, up to 0.99, up to 0.95, e.g., 0.80-1.019, or 0.80-1.015, or 0.80-1.01, or 0.80-1.005, or 0.80-1.00, or 0.80-0.95, or 0.80-0.9, or 0.80-1.015, or 0.90-1.01, or 0.90-1.005, or 1.005-1.015).

[0038] The low yield carbon black feedstock may have only BMCI properties. The low yield carbon black feedstock may have only atomic H:C properties. The low yield carbon black feedstock may have only specific gravity properties. The low yield carbon black feedstock may have only gas properties.

[0039] The low yield carbon black feedstock can have BMCI and atomic H:C characteristics.

[0040] The low yield carbon black feedstock can have BMCI and specific gravity characteristics.

[0041] The low yield carbon black feedstock can have BMCI and gas properties.

[0042] The low yield carbon black feedstock can have BMCI characteristics, atomic H:C characteristics, and specific gravity characteristics.

[0043] The low yield carbon black feedstock can have BMCI properties, atomic H:C properties, and gas properties.

[0044] The low yield carbon black feedstock can have BMCI characteristics, atomic H:C characteristics, specific gravity characteristics, and gas characteristics.

[0045] The low yield carbon black feedstock can have atomic H:C characteristics and specific gravity characteristics.

[0046] The low yield carbon black feedstock can have atomic H:C characteristics as well as gaseous characteristics.

[0047] The low yield carbon black feedstock can have atomic H:C characteristics, specific gravity characteristics, and gas characteristics.

[0048] The low yield carbon black feedstock can have density and gaseous properties.

[0049] The low-yield carbon black feedstock can be a feedstock that is derived from what is considered to be a sustainable, biological, and / or recycled source. For example, the low-yield carbon black feedstock can be or can include ethylene, which is a gas at room temperature and pressure. Ethylene can be produced from bio-derived ethanol, for example, from corn fermentation, or other plant material fermentation. Another example of a low-yield carbon black feedstock is natural gas.

[0050] For purposes of this invention, a low yield carbon black feedstock may be a feedstock that is not derived from fossil fuel based gasoline production or coal cracking, or cracking to produce olefins. Thus, a low yield carbon black feedstock is a feedstock other than coal tar liquor, petroleum refinery liquid, or ethylene cracker residue.

[0051] Other examples of low yield liquid carbon black feedstocks may include, but are not limited to, the following: tire pyrolysis oil, plastic pyrolysis oil, recycled oil, algae oil, vegetable-derived oil, oil derived from the pyrolysis of municipal solid waste, oil derived from the pyrolysis or decay of biomass (e.g., animal or plant) or agricultural waste, oil derived from the processing of pulp or paper manufacturing by-products, and / or other oils sourced primarily from biological materials, or any combination thereof. Exemplary low yield feedstocks include, but are not limited to, vegetable oils or oils derived from other plants, bio-derived ethanol, plant or animal waxes or resins, oils derived from animal fats, algae oil, oils derived from pyrolysis of sewage sludge or agricultural waste, by-product liquids from the processing of biogenic materials, liquids produced by hydrothermal liquefaction of biomaterials, crude tall oil, tall oil rosin, tall oil pitch or tall oil fatty acids, oils derived from recycled materials, oils derived from pyrolysis of low quality, rejected or end of life tires, oils derived from pyrolysis of discarded or recycled plastic or rubber products, oils derived from pyrolysis of municipal solid waste, or oils derived from pyrolysis of biomass, or any combination thereof. These liquid feedstocks have an atomic H:C ratio greater than 1.23 or a specific gravity of up to 1.02 or a BMCI value less than 100. Specific examples of liquid low yield carbon black feedstocks are shown in Table 1 below. [Table 1]

[0052] Figure 1 is a graph showing the atomic H:C ratios of conventional high-yield carbon black feedstocks compared to tire pyrolysis oil (TPO), vegetable oil (Veg.Oil), and two gas-phase feedstocks (natural gas and ethylene) (Gas). For conventional feedstocks, H:C is plotted for a collection of approximately 1000 representative coal tar liquors, decant oils, and ECRs used as carbon black feedstocks for the furnace black process between 2016 and 2021. The range of H:C values ​​can be compared to three groups of low-yield carbon black feedstocks. It is clear that the conventional feedstocks have low H:C values ​​of 1.23 or less (dashed lines in the figure). All low-yield carbon black feedstocks in Figure 1 have H:C values ​​above 1.23.

[0053] FIG. 2 is a graph showing examples of specific gravities of conventional high-yield feedstocks compared to tire pyrolysis oil (TPO) and vegetable oil (Veg.Oil). For conventional feedstocks, specific gravities are plotted for a collection of approximately 1000 representative coal tar liquids, decant oils, and ECRs used as carbon black feedstocks for the furnace black process between 2016-2021. The specific gravity ranges are compared to two groups of low-yield carbon black feedstocks. It is clear that conventional feedstocks generally have specific gravities greater than 1.02 (dashed lines in the figure), while the low-yield carbon black feedstocks have specific gravities below 1.02.

[0054] FIG. 3 is a graph showing examples of BMCI numbers of conventional high-yield feedstocks compared to tire pyrolysis oil (TPO) and vegetable oil (Veg.Oil). For conventional carbon black feedstocks, BMCI numbers are plotted for a collection of approximately 1000 representative coal tar liquors, decant oils, and ECRs used as feedstocks for the furnace black process between 2016 and 2021. Their BMCI values ​​are compared to two low-yield feedstock groups. Almost all conventional feedstocks have BMCI values ​​greater than 110, and all examples shown here have BMCI numbers greater than 100 (dashed lines). In contrast, the TPO and vegetable oil groups have BMCI numbers less than 100.

[0055] Other examples of low yield carbon black feedstocks can include, but are not limited to, renewable feedstocks, bio-derived or bio-based feedstocks, and / or other by-products of refinery processes, or any combination thereof.

[0056] Other examples of low yield carbon black feedstocks can include, but are not limited to, the following: vegetable oils or oils derived from other plants (e.g., corn oil and / or corn distillate oil).

[0057] Other examples of low yield carbon black feedstocks can include, but are not limited to, the following: bio-derived ethanol (derived from corn fermentation or fermentation products from other plants, vegetables, or fruits).

[0058] Other examples of low yield carbon black raw materials can include, but are not limited to, the following: vegetable or animal waxes and resins, such as lanolin or lac.

[0059] Other examples of low yield carbon black feedstocks can include, but are not limited to, the following: oils obtained from animal fats.

[0060] Other examples of low yield carbon black feedstocks can include, but are not limited to, the following: algae oil.

[0061] Other examples of low yield carbon black feedstocks can include, but are not limited to, the following: oil obtained from pyrolysis of sewage sludge or agricultural waste.

[0062] Other examples of low yield carbon black feedstocks can include, but are not limited to, the following: by-product liquids from the processing of biogenic materials.

[0063] Other examples of low yield carbon black feedstocks can include, but are not limited to, the following: liquids produced by hydrothermal liquefaction of biomaterials.

[0064] Other examples of low yield carbon black feedstocks can include, but are not limited to, the following: crude tall oil, tall oil rosin, tall oil pitch, or tall oil fatty acids (e.g., from the papermaking process).

[0065] Other examples of low yield carbon black feedstocks can include, but are not limited to, the following: renewable feedstocks, such as oils obtained from recycled materials.

[0066] Other examples of low yield carbon black feedstocks can include, but are not limited to, the following: oils obtained from the pyrolysis of low quality, rejected, or end of life tires.

[0067] Other examples of low yield carbon black feedstocks can include, but are not limited to, the following: oils obtained from the pyrolysis of waste or recycled plastics.

[0068] Other examples of low yield carbon black feedstocks can include, but are not limited to, the following: oil obtained from pyrolysis of municipal solid waste.

[0069] Other examples of low yield carbon black feedstocks can include, but are not limited to, the following: oils (bio-oils) obtained from the pyrolysis of biomass, e.g., animals or plants (e.g., vegetables).

[0070] As noted above, in the present invention, a portion (by weight %) of the total feedstocks utilized in the process of the present invention (whether introduced in a stepwise manner or as a blend, or introduced at the same or nearly the same location in the reactor) are one or more low yield carbon black feedstocks and a portion is not a low yield carbon black feedstock.

[0071] For purposes of this invention, "approximately the same location" means that the introduction of multiple feedstocks occurs at the same location (I1) or within 5% of I1, based on the overall length of the carbon black reactor.

[0072] Preferably, the amount of low yield carbon black feedstock (introduced in a stepwise manner, or as a blend, or introduced at or about the same location in the reactor) is at least 10% by weight, or at least 15% by weight, or at least 20% by weight, or at least 25% by weight, or at least 30% by weight, or at least 35% by weight, or at least 40% by weight, or at least 45% by weight, or at least 50% by weight, or at least 55% by weight, or at least 60% by weight, or at least 65% by weight, or at least 70% 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, preferably less than 99% by weight or less than 95% by weight, e.g. , 10% by weight to 95% by weight, or 10% by weight to 90% by weight, or 15% by weight to 90% by weight, or 20% by weight to 90% by weight, or 25% by weight to 90% by weight, or 30% by weight to 90% by weight, or 35% by weight to 90% by weight, or 40% by weight to 90% by weight, or 45% by weight to 90% by weight, or 50% by weight to 95% by weight, or 10% by weight to 80% by weight, or 10% by weight to 70% by weight, or 10% by weight to 60 %, or 10% by weight to 50% by weight, or 10% by weight to 40% by weight, or 10% by weight to 30% by weight, or 60% by weight to 95% by weight, or 65% by weight to 95% by weight, or 70% by weight to 95% by weight, or 75% by weight to 95% by weight, or 60% by weight to 95% by weight, or 60% by weight to 90% by weight, or 60% by weight to 85% by weight, or 60% by weight to 80% by weight, or 60% by weight to 75% by weight, etc.

[0073] For purposes of this invention, a "first carbon black feedstock" or "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 referred to as a carbon black feedstock traditionally used in furnace carbon black processes ("traditional" carbon black feedstocks). As discussed further herein, the first carbon black feedstock may optionally be a blend of feedstocks that contains a small amount of a low yield carbon black feedstock.

[0074] The first carbon black feedstock is usually from the family of decanted or slurry oils, coal tar or coal tar distillate fractions, or ethylene or phenol cracker residues. With regard to carbon black production in a typical furnace process, their defining characteristics are further described below.

[0075] The first carbon black raw material has all three of the following characteristics: 1) at least 100 (e.g., 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, e.g., 100 to 180, 101 to 180, 102 ~180, 103~180, 104~180, 105~180, 110~180, 115~180, 120~180, 130~180, 140~180, 150~180, 160~180, 100~175, 100~170, 100~165, 110~175, 115~175, 120~175, 125~170, 130~170) BMCI, 2) A specific gravity of more than 1.02 (e.g., more than 1.025, more than 1.03, more than 1.035, more than 1.04, or more than 1.05, e.g., 1.021 to 1.3, or 1.025 to 1.3, or 1.03 to 1.3, or 1.05 to 1.3, or 1.07 to 1.25); 3) C:H ratio of up to 1.23 (e.g., up to 1.22, up to 1.21, up to 1.2, up to 1.15, up to 1.1, up to 1.05, up to 1, up to 0.9, up to 0.8, e.g., 1.225-0.7, 1.225-0.8, 1.225-0.9, 1.225-1, 1.225-1.1, 1.22-0.7, 1.21-0.7, 1.2-0.7). As an option, the first carbon black feedstock can also be a liquid at room temperature and pressure (e.g., 25° C. and 1 atm). Although a liquid, the first carbon black feedstock can be a pitch or similar material having a very high viscosity and does not need to exhibit significant flowability.

[0076] Examples of first carbon black feedstocks are shown in Table 2 below and include coal tar, liquids distilled from coal tar, decant or slurry oils obtained from catalytic cracking, and residual oils from ethylene cracking. As shown in Table 2, these feedstocks have an H:C of up to 1.23, specific gravities greater than 1.02, and BMCI values ​​of at least 100.

[0077] [Table 2]

[0078] The first carbon black feedstock may also include fractions obtained from refining or distilling tire pyrolysis oil. Pyrolysis may be accomplished by any method known to those skilled in the art. Exemplary methods include, but are not limited to, those found in U.S. Pat. No. 8,350,105 and U.S. Patent Publication No. 20180320082, the entire contents of both of which are incorporated herein by reference. Distillation of the resulting oil may also be accomplished by any method known to those skilled in the art. Exemplary methods include, but are not limited to, those found in U.S. Pat. No. 9,920,262, WO 2019236214, the contents of which are incorporated herein by reference. 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. Indeed, distillation may result in lighter fractions that may be more economically used in other unit processes of the carbon black manufacturing process, such as as fuel for a dryer for the carbon black or for a heater to preheat either the first carbon black feedstock or the second carbon black feedstock or both, as disclosed in U.S. Patent Application Publication No. 20130039841, the contents of which are incorporated herein by reference. Thus, integration of the distillation process with the carbon black reactor may balance the economic and environmental benefits from recycling carbon black filled tires.

[0079] Alternatively, in the process of the present invention, based on the total amount of raw materials utilized (in weight percent), the first carbon black raw material comprises 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.%, based on the total weight percent of all raw materials used. , 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, preferably less than 99% by weight or less than 95% by weight, for example, 10% to 95% by weight, or 10% to 90% by weight, or 15% to 90% by weight, or 20% to 90% by weight, or 25% to 90% by weight, or 30% to 90% by weight, or 35% to 90% by weight, or 40% to 90% by weight, or 45% to 90% by weight, or 50% to 95% by weight, or 10% to It may be used in an amount of 80% by weight, or 10% to 70% by weight, or 10% to 60% by weight, or 10% to 50% by weight, or 10% to 40% by weight, or 10% to 30% by weight, or 60% to 95% by weight, or 65% to 95% by weight, or 70% to 95% by weight, or 75% to 95% by weight, or 60% to 95% by weight, or 60% to 90% by weight, or 60% to 85% by weight, or 60% to 80% by weight, or 60% to 75% by weight, etc. (introduced in a stepwise manner or as a blend, or in a reaction The other amount of the first carbon black feedstock, based on the total amount of feedstock utilized (in weight percent), can be 49% by weight or less, 45% by weight or less, 40% by weight or less, 35% by weight or less, 30% by weight or less, 25% by weight or less, 20% by weight or less, 15% by weight or less, 10% by weight or less, 9% by weight or less, 8% by weight or less, 7% by weight or less, 6% by weight or less, for example, 5% by weight to 49% by weight, or 5% by weight to 45% by weight, or 10% by weight to 40% by weight, or 10% by weight to 35% by weight, or 10% by weight to 30% by weight.

[0080] The first carbon black feedstock may be liquid under room temperature (e.g., 25° C.) and atmospheric (e.g., 1 atm) conditions. By “rich in aromatics” it is meant that the feedstock comprises a majority of aromatic compounds present. For example, a majority of aromatic compounds may have a total weight percent of aromatic compounds present of at least 20 weight percent, or a BMCI of at least 100, or both. The first carbon black feedstock may be heated such that the feedstock is in vapor form, which may result in an aromatics-rich vapor, or may actually be used as an aromatics-rich vapor.

[0081] With respect to the steps of the inventive method, some methods of the present invention include combining an electrically heated gas stream (or an electrically heated carrier gas stream) with a first carbon black feedstock and a low-yield carbon black feedstock. As further explained above, the first carbon black feedstock and the low-yield carbon black feedstock can be introduced or combined into the heated gas stream in a staged manner (e.g., the first carbon black feedstock is introduced first and then the low-yield carbon black feedstock is introduced downstream, or a blend of the first carbon black feedstock and the low-yield carbon black feedstock is introduced or combined into the heated gas stream), or the first carbon black feedstock and the low-yield carbon black feedstock are introduced or combined into the heated gas stream at or near the same location within the carbon black reactor).

[0082] In another method of the present invention, the carbon black feedstock, or a portion thereof, is electrically heated to cause pyrolysis of the feedstock.

[0083] In the process of the present invention, the electrically heating of either the carrier gas and / or the carbon black feedstock can be such that the electrically heating is direct or indirect (e.g., direct means that a heating element contacts the carrier gas and / or the feedstock).

[0084] There are at least four methods that can be utilized for purposes of the present invention to generate an electrically heated gas stream. In all methods, electrical energy is utilized to heat the carrier gas and / or the raw carbon black material such that pyrolysis of at least a portion of the raw carbon black material occurs.

[0085] The present invention can be implemented in several variations or embodiments.

[0086] In the first method, an arc is used to electrically heat a carrier gas, which can then be contacted with the carbon black feedstock(s) described herein. Because the arc creates a plasma, this method is sometimes referred to as a plasma process.

[0087] In the second method, the carrier gas is electrically heated using either a resistive or inductive heating element and then the carrier gas is contacted with the carbon black raw material as described herein.

[0088] The third method uses an inductive or microwave-based plasma to heat either the carrier gas or the carbon black feedstock itself without direct contact between the gas and an electrode.

[0089] In the fourth method, a plasma arc or heating element is in direct contact with the carbon black feedstock and is used to heat the feedstock. U.S. Patent No. 8,221,689 and U.S. Patent No. 7,563,525 further describe these methods that may be utilized in the present invention.

[0090] The processes utilized to form or generate the electrically heated gas stream and / or the carbon black feedstock, as well as the apparatus / devices and conditions / parameters for doing so, are commercially available and can be adapted or utilized herein for the process of the present invention.

[0091] In more detail, and merely by way of example, examples of the first method (plasma process with carrier gas) and the second method (electrical heating process with carrier gas) will now be described in more detail.

[0092] The plasma process may be used to produce carbon black by heating a suitable carrier gas stream to high temperatures such that when combined with an electrically heated carrier gas stream (e.g., 3000° C. or higher), pyrolysis of the carbon black feedstock may occur. Heating may be accomplished by an electric arc. Once the heated carrier gas stream is formed, the carbon black feedstock may be introduced into or combined with the heated carrier gas stream. The hot carrier gas stream contains a significant portion of the energy required to drive the rapid high temperature pyrolysis of the feedstock into carbon black and by-product gases. Further details of this process that may be employed in the method of the present invention are described in U.S. Pat. No. 9,574,086, which is incorporated herein by reference in its entirety.

[0093] An example of a setup and reactor for a plasma process 10 is shown in Figure 4, which shows a cross-section of a carbon black reactor 10. A carrier gas, such as hydrogen or argon, is introduced, for example, via duct 2, into a plasma generation chamber 6 of diameter 5. The bulk flow of material is in direction A. An electrode 3 creates an electric arc 4 that heats the carrier gas, typically into a plasma state.

[0094] The heated carrier gas is then combined or mixed with the carbon black feedstock, which may be introduced, for example, by injectors 7 and 8. Injector 7 may be located at a location having a diameter narrower than diameter 5. In FIG. 4, injector 8 is shown downstream of injector 7 at throat 9, which has the narrowest diameter of the carbon black reactor 10. Alternatively, injector 8 may be located downstream of injector 7, but in a region having a diameter wider than throat 9. Injector 7 may, for example, introduce or inject a first carbon black feedstock into the reactor, and an additional carbon black feedstock, for example a low yield carbon black feedstock, may be introduced at injection point 8. The distance between injectors 7 and 8 need only be long enough for the first carbon black feedstock injected into reactor 10 at injector 7 to be mixed into the carrier gas. In the present invention, generally, at least a portion, if not all, of the first carbon black feedstock may be injected or introduced at least before the low yield carbon black feedstock is introduced into the reactor. Preferably, the majority of the first carbon black feedstock is introduced before any low yield carbon black feedstock is introduced. To aid in this mixing process, a hot carrier gas can be forced into the narrow throat 9 to increase turbulence and create high speed mixing. Because the first carbon black feedstock is typically injected as a liquid, the increased turbulence created by the contraction can also aid in atomization of the droplets.

[0095] After injection of the first and low yield carbon black feedstocks, the mixed flow of hot carrier gas and reactant feedstock enters a suitable reaction chamber 14 having a diameter 11. Diameter 11 and diameter 5 can be substantially larger than the diameter of throat 9. At a location 12 downstream of the final feedstock injection point, the mixture is quenched using a gas or liquid spray 13.

[0096] Throat 9 in Figure 4 is optional and may not be used. As an option, a single injection point (e.g., either injection point 7 or injection point 8) may be used to introduce the first and low yield carbon black feedstocks as a blend. As another option, more than the two injection points for the feedstocks shown at 7 and 8 may be used.

[0097] It is possible to completely or partially replace the plasma heating device of FIG. 4 with a system 15 made of electrical resistance heating wires or induction heating elements, as shown in FIG. 5, which shows a cross section of another reactor 15. The process and the device are similar to those of FIG. 4, except that the carrier gas is heated differently than the plasma generating arc. FIG. 5 shows a set of resistance heating elements 16 (e.g. rods) arranged in the path of the carrier gas introduced through a duct (not shown) in a similar manner to the device of FIG. 4. In FIG. 5, the resistance heating elements 16 heat the carrier gas flowing in the direction A. After the step of heating the carrier gas, the process may be the same as that described in connection with FIG. 4. Alternatively or additionally, ceramic heating elements such as magnesium oxide or yttria stabilized zirconia may be used.

[0098] The elements 16 may be heated by subjecting them to an electric current passing through them, or may be inductively heated, for example, by subjecting them to microwave, radio frequency, or other suitable electromagnetic radiation. As is known in the art, the electromagnetic energy in microwave radiation causes electrons to move within the rods, heating them. This method allows for a reactor without direct penetrations for electrical connections, which may be beneficial in certain instances. For example, SiC rods heat up when subjected to microwave radiation. In this embodiment, there is no need to have crossing wires or other conductors within the heating chamber, thus reducing design complexity.

[0099] The method of the present invention can be applied to electrically heated processes and reactors as shown in Figure 6. Figure 6 shows a cross-sectional view of another example of a carbon black reactor 20 with similar features as the apparatus 10 of Figure 4. In contrast to Figure 4, the reactor 20 features two contracting throats 64 and 65 with narrowing diameters at either end of the intermediate chamber 58. Hot carrier gas from duct 2 is fed towards the contracting throat 64. A first carbon black feedstock is fed through injector 7 or 8, or both simultaneously, and mixed with the carrier gas.

[0100] In FIG. 6, the length between the introduction of the carrier gas and the center of the contraction 64 is shown as length 60. This length can preferably be 1 to 10 times the narrowest diameter of the first contraction 64. Adjusting this length allows for balancing of carbon black structure and process economics. Height or diameter 5 is shown relative to the heated gas chamber, this height is greater than height or diameter 64. Height or diameter 64 can be at least 20%, at least 30%, at least 40%, at least 50% less than height or diameter 5.

[0101] Following the introduction of the first carbon black feedstock, the hot gas stream mixed with the feedstock enters the first reaction chamber 58. The purpose of the chamber is to provide a residence time to allow the pyrolysis reactions producing the carbon black to complete an induction period and begin, and optionally to produce a seed particle population for subsequent structure growth. The length of this chamber 66 can typically be 1 to 20 times the narrowest diameter of the first constriction 64.

[0102] At the end of the first reaction chamber 58, the low yield carbon black feedstock can be introduced. It may be introduced using an injector or injector array 59 located in or near the second constriction 65 and / or substantially downstream from the first positions 7 and / or 8. Alternatively, the low yield carbon black feedstock may be introduced using a lance into the chamber 58, but substantially upstream of the constriction 65.

[0103] The distance 66 between the contracting throats 64 and 65 can be larger than the diameter 64 and can be adjusted to change or optimize product characteristics. The contracting throats 64 and 65 can have the same or different diameters. One skilled in the art will recognize how to adjust these diameters to obtain the desired mixing characteristics of the reacting streams.

[0104] After introduction of the low yield carbon black feedstock, the mixture flows into a second reaction chamber 61. It is then quenched using a cooling spray of liquid or vapor 62, as known in the art. The length from the injection point 59 of the low yield carbon black feedstock to the quench location 62 is shown at 67 in Figure 6. This length is set to provide a residence time that controls certain product characteristics, as known in the art.

[0105] In another arrangement, the first carbon black feedstock is introduced at position 7 and / or position 8, and then the low-yield carbon black feedstock is introduced at positions 8 and / or 59 (and / or at positions between these positions), which can also be introduced simultaneously if both positions are used. This can provide a beneficial trade-off between build capacity and yield or process economics. In all of the above embodiments, at least a portion, preferably a majority, of the first carbon black feedstock used, for example all of the first carbon black feedstock, is introduced before and upstream of the low-yield carbon black feedstock.

[0106] Using the present invention, the process allows gas phase carbon black feedstocks, or other non-traditional, low yield carbon black feedstocks, to produce larger carbon black structures than are achievable in conventional processes that may use the non-traditional carbon black feedstocks.

[0107] Additionally, the present invention allows for a reduction in the temperature required to produce a given surface area compared to the exclusive use of non-traditional feedstocks. This means less carrier gas is required, lowering capital costs in the electrically heated process. For example, temperatures can be reduced by 2% to 5% or more.

[0108] The injector 7 can, for example, introduce or inject the first carbon black feedstock into the reactor. Alternatively, the first carbon black feedstock can also be introduced into the chamber using an axial pipe or lance. As a further alternative, the first carbon black feedstock can be injected or introduced simultaneously by multiple methods. 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.

[0109] In the present invention, optionally, at least a portion (but not all) of the first carbon black feedstock may be injected or introduced prior to the introduction of the low yield carbon black feedstock into the reactor. Preferably, the amount of first carbon black feedstock injected or introduced into the reactor prior to the introduction of the low yield carbon black feedstock is greater than the total amount of first carbon black feedstock introduced at any subsequent stage. That is, the majority (>50%) of the first carbon black feedstock used in the reactor is introduced or injected in a first stage (e.g., at location / injector 7 in FIG. 4).

[0110] The carbon black feedstock can be injected into the gas stream through one or more nozzles designed for optimal distribution of the feedstock into the heated carrier gas stream. Such nozzles can be either single-fluid or dual-fluid. Dual-fluid nozzles can use, for example, steam, air, or nitrogen to atomize the feedstock. Single-fluid nozzles can be pressure atomized or the feedstock can be directly injected into the gas stream. In the latter case, atomization occurs due to the force of the gas stream.

[0111] The carbon black feedstock may be injected by an axial injection lance, or a central pipe may be used, and / or one or more radial lances arranged around the reactor in a plane perpendicular to the flow direction. The reactor may include several planes with radial lances along the flow direction. Atomizing or injection nozzles may be located at the heads of the lances, whereby the feedstock is mixed into the heated gas stream.

[0112] The first carbon black feedstock can be introduced at one or more of these locations, or at two of the locations simultaneously, or at three or more locations simultaneously. The mode and split of first feedstock injection can be varied between the locations, if more than one location is used, to modify product properties and process economics. The injectors and reaction chamber itself(s) can be cooled as needed by methods known in the art.

[0113] In yet another example of the present invention, the first carbon black feedstock may be a blend of a high yield carbon black feedstock and a low yield carbon black feedstock satisfying the BMCI, specific gravity, and H:C parameters described above, provided that the blend satisfies the BMCI, specific gravity, and H:C parameters described above for the first carbon black feedstock. The blend may contain more than 50% by weight of the high yield carbon black feedstock (e.g., 50.5% to 99.5% by weight, such as 60% to 99% by weight).

[0114] Similarly, the low yield carbon black feedstock may optionally be a blend of a high yield carbon black feedstock with a non-high yield carbon black feedstock that does not meet at least one of the BMCI, H:C 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, H:C and specific gravity parameters required for the first carbon black feedstock. The non-high yield carbon black feedstock may be present in an amount greater than 50% by weight (e.g., 50.5% to 99.5% by weight of the non-high yield carbon black feedstock, such as 60% to 99% by weight) of the total feedstocks of any blend.

[0115] Additionally, optionally, the total amount of the first carbon black feedstock introduced into the reactor through the sum of all injection locations can be less than 50% by weight based on the total amount of carbon black feedstock used at any location in the reactor. The total amount of the low yield carbon black feedstock can be more than 50% by weight based on the total feedstock.

[0116] Alternatively, in one method of the present invention, the method includes the step of introducing at least one first carbon black feedstock into a carbon black reactor with the heated gas stream to form a reaction stream. The first carbon black feedstock may be one or a combination of two or more different first carbon black feedstocks. When more than one type of feedstock is utilized as the first carbon black feedstock, the first carbon black feedstocks may be blended together and injected as one blended feed through one or more locations, or each feedstock may be injected separately into the reactor at the same or different locations.

[0117] Alternatively, in one method of the invention, the method includes the step of introducing at least one low yield carbon black feedstock into the 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 more than one type of feedstock is utilized as the low yield carbon black feedstock, the multiple low yield carbon black feedstocks may be blended together and injected as one blended feed through one or more locations, or each feedstock may be injected separately into the reactor at the same or different locations.

[0118] Generally, any of the carbon black feedstocks utilized in any of the processes of the present invention can be injected into the reactor in a single or multiple streams using injectors that penetrate into the interior region of the heated gas stream. The injectors can better ensure high mixing and shear between the heated gas stream and the carbon black feedstock(s). This ensures that the feedstocks preferably pyrolyze at a fast rate and / or high yield to form the carbon black of the present invention.

[0119] The first carbon black feedstock can be introduced at one location in the reactor or at multiple locations in the reactor. In one embodiment of the invention, the low-yield carbon black feedstock can be introduced at one location in the reactor or at multiple locations in the reactor. As indicated, in this method of the invention, the one or more locations in the reactor can be downstream(s) of the one or more locations where the first carbon black feedstock is injected or introduced. The introduction of the low-yield carbon black feedstock can be done using one or more injectors (e.g., metal pipe(s) located on the wall of the reactor) that introduce the feedstock into the reactor. The injector can have an injector head or spray head at the tip. The injector on the tip can have, for example, one or more holes (two or three or four or more) around the circumference of the tip (multiple holes roughly evenly spaced apart).

[0120] As an option, introduction of the low yield carbon black feedstock into the reactor and reaction stream can be such that the feedstock is introduced perpendicular to the lateral flow of the reaction stream through the reactor, for example, as shown in Figures 4-6, where perpendicular can be ±15 degrees from true perpendicular injection of the feedstock into the reaction stream.

[0121] As an option, the introduction of the low yield carbon black feedstock into the reactor can be at a location that has a narrower diameter than the diameter of the reactor where the first carbon black feedstock was previously introduced. For example, injector 8 in FIG. 4 is in a narrower portion of reactor 10 than injector 7. This location can be considered the "throat" in some carbon black reactors. This narrower diameter can have a diameter that is at least 10% smaller, at least 20% smaller, or at least 30% smaller, or between 10% and 40% smaller than the diameter of the reactor where the first carbon black feedstock was previously introduced.

[0122] Alternatively, the introduction of the low yield carbon black feedstock into the reactor and reaction stream can be at a distance from the location in the reactor where the first carbon black feedstock is introduced or injected, which distance can be at least 1 or at least 2 times the narrowest diameter of the first chamber 6 of the reactor, e.g., diameter 9 or 64 (or at least twice the diameter of the reactor where the first carbon black feedstock is introduced or injected). This distance can 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 first chamber of the reactor (e.g., where the carrier gas or feedstock is electrically heated) (or 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 where the first carbon black feedstock is introduced or injected).

[0123] The low yield carbon black feedstock may be introduced at positions 8 and / or 59 through one or more injectors.

[0124] After the feedstocks (the first carbon black feedstock and the low yield carbon black feedstock) are combined with the heated gas stream, the process of the present invention generally includes a step of quenching the reaction.

[0125] The reaction is stopped in a quench zone (see 62 in FIG. 6) of the reactor. As shown in FIG. 6, the quench 62 is located downstream of the last feed injection zone and sprays a quench fluid, such as water, into the stream of newly formed carbon black particles. In general, the quench serves to cool the carbon black particles, reduce the temperature of the gas stream, and slow the reaction rate. Distance 67 is the distance from the beginning of the last feed injection point to the quench point 62 and varies depending on the location of the quench. Optionally, the quench may be staged or may occur at several points in the reactor. Pressure spray, gas atomized spray, or other quenching techniques may also be utilized. With regard to completely quenching the reaction to form carbon black, any means known to those skilled in the art for quenching a reaction downstream of the introduction of the carbon black manufacturing feedstock may be used. For example, a quench fluid, which may be water or other suitable fluid, may be injected to stop the chemical reaction.

[0126] After quenching, the cooled gas and carbon black are passed downstream to any conventional cooling means 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 other means known to those skilled in the art. After the carbon black is separated from the gas stream, it can optionally be subjected to a pelletization step.

[0127] For any of the methods of the present invention, as an option, the carbon black produced is not a carbon black having a core and a coating.

[0128] For any of the processes of the present invention, optionally the carbon black is formed entirely in situ in the reactor.

[0129] Optionally, any one or more of the carbon black feedstock or other components used in the process of the present invention may be preheated prior to introduction into the reactor, see, for example, U.S. Patent No. 3,095,273 issued to Austin on June 25, 1963, U.S. Patent No. 3,288,696 issued to Orbach on November 29, 1966, U.S. Patent No. 3,984,528 issued to Cheng et al. on October 5, 1976, U.S. Patent No. 4,315,901 issued to Cheng et al. on February 16, 1982, U.S. Patent No. 4,765,964 issued to Gravley et al. on August 23, 198 ... Suitable preheating temperatures and / or techniques can be used in the present invention, as described in 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 Godal et al., U.S. Patent No. 8,871,173(B2) issued October 28, 2014 to Nester et al., or Canadian Patent No. 682982 (all documents incorporated herein by reference). Alternatively, or in addition, the low yield carbon black feedstock may be preheated to a temperature higher than typical for high yield feedstocks. For example, the low yield carbon black feedstock may be heated to a temperature in excess of 600° C., e.g., 600-800° C., even at ambient pressure. Because the low yield carbon black feedstock has a low concentration of asphaltenes, heating to such high temperatures does not produce significant amounts of coke or other solid non-carbon black species. Alternatively or additionally, any one or more of the carbon black raw materials may be combined with an extender fluid prior to being introduced into the reactor, as described, for example, in U.S. Pat. No. 10,829,642 to Unrau, the entire contents of which are incorporated herein by reference.

[0130] Optionally, the method is carried out in the absence of at least one substance that is or contains at least one Group IA or Group IIA element (or an ion thereof) of the periodic table.

[0131] Alternatively, in any of the methods of the present invention, the method may include the step of introducing at least one substance that is or contains at least one Group IA or Group IIA element (or ion thereof) of the periodic table. Preferably, the substance contains at least one alkali metal or alkaline earth metal. Examples include lithium, sodium, potassium, rubidium, cesium, francium, calcium, barium, strontium, or radium, or combinations thereof. Any mixture of one or more of these components may be present in the substance. Such substances may be solids, solutions, dispersions, gases, or any combinations thereof. Two or more substances with the same or different Group IA or Group IIA metals may be used. When multiple substances are used, the substances may be added together, separately, sequentially, or at different reaction locations. For 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), etc. Preferably, the material is one that is capable of introducing a metal or metal ion into the ongoing reaction to form the carbon black product. For purposes of the present invention, preferably the material is introduced prior to the complete quench as described above. For example, the material can be added at any time prior to the complete quench, including prior to the introduction of one or both of the carbon black making raw materials, during the introduction of either or both of the carbon black making raw materials, after the introduction of any or all of the carbon black making raw materials, or after the introduction of all raw materials but prior to the complete quench. More than one introduction point of the material can be used. The amount of Group IA or Group IIA metal-containing material can be any amount so long as a carbon black product can be formed. For example, the amount of material can be added such that 200 ppm or more of Group IA or Group IIA element is present in the carbon black product ultimately formed.Other amounts of Group IA or Group IIA elements present in the formed carbon black product include from about 200 ppm to about 5000 ppm or more, with other ranges being from about 300 ppm to about 1000 ppm, or from about 500 ppm to about 1000 ppm. These levels can be in terms of metal ion concentrations. As noted above, these amounts of Group IA or Group IIA elements present in the formed carbon black product can be in terms of one element or more than one Group IA or Group IIA element, and therefore the total amount of Group IA or Group IIA elements present in the formed carbon black product. The material can be added in any manner, including any conventional means. In other words, the material can be added in the same manner that the carbon black production feedstock is introduced. The material can be added as a gas, liquid, or solid, or any combination thereof. The material can be added at one or several points, and can be added as a single stream or multiple streams. The material can be mixed with the feedstock, fuel, and / or oxidizer before or during their introduction.

[0132] With respect to the carbon black formed by any of the methods of the present invention, the carbon black formed or produced can be any reinforced or non-reinforced grade of carbon black. Examples of reinforced grades are N110, N121, N220, N231, N234, N299, N326, N330, N339, N347, N351, N358, and N375. Examples of semi-reinforced grades are N539, N550, N650, N660, N683, N762, N765, N774, N787, and / or N990.

[0133] Carbon black can be characterized by specific surface area, structure, aggregate size, shape, and distribution, and / or surface chemical and physical properties. Carbon black properties are analytically determined 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 ASTM test procedure D6556. Iodine number can be measured using ASTM procedure D1510. Carbon black "structure" refers to the size and complexity of 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 (OAN) of unground carbon black, expressed as milliliters of oil per 100 grams of carbon black, according to the procedure described in ASTM D2414. Compressed oil absorption (COAN) measures the portion of carbon black structure that is not easily altered by the application of mechanical stress. COAN is measured according to ATSM D3493. Aggregate size distribution (ASD) is measured according to the ISO 15825 method using a disc centrifuge photosedimentometer equipped with a model BI-DCP manufactured by Brookhaven Instrument.

[0134] Carbon black materials having suitable properties for a particular 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 series carbon blacks, such as N110, 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 standards.

[0135] Carbon black is 5m 2 / g~250m 2 / g, 11m 2 / g~250m 2 / g, 20m 2 / g~250m 2 / g or more, e.g., at least 70m 2 / g, e.g., 70m 2 / g~250m 2 / g, or 80m 2 / g~200m 2 / g, or 90m 2 / g~200m 2 / g, or 100m 2 / g~180m 2 / g, 110m 2 / g~150m 2 / g, 120m 2 / g~150m 2 The carbon black can have any STSA, such as in the range of about 100 mg I2 / g, etc. Optionally, the carbon black can have an iodine number (I2 No) of about 5 to about 35 mg I2 / g carbon black (per ASTM D1510).

[0136] The carbon black particles disclosed herein have a 5 mm viscosity, as measured by the Brunauer / Emmett / Teller (BET) technique according to the procedure of ASTM D6556. 2 / g~300m 2 / g, e.g., 50m 2 / g~300m 2 / g, e.g., 100m 2 / g~300m 2 The BET surface area can be about 100 m / g. 2 / g~about 200m 2 / g or about 200m 2 / g~about 300m 2 / g.

[0137] The oil absorption (OAN) can be 40 mL / 100g to 200 mL / 100g, for example, 60 mL / 100g to 200 mL / 100g, for example, 80 mL / 100g to 200 mL / 100g, for example, 100 mL / 100g to 200 mL / 100g, or 120 mL / 100g to 200 mL / 100g, mL / 100g, 140 mL / 100g to 200 mL / 100g, 160 mL / 100g to 200 mL / 100g, or for example, 40 mL / 100g to 150 mL / 100g, or 40 mL / 100g to 150 mL / 100g.

[0138] The COAN can be within the range of about 40 mL / 100 g to about 150 mL / 100 g, for example, about 55 mL / 100 g to about 150 mL / 100 g, for example, about 80 mL / 100 g to about 150 mL / 100 g, or about 80 mL / 100 g to about 120 mL / 100 g.

[0139] Carbon black can be a carbon product containing silicon-containing species and / or metal-containing species, etc., which can be accomplished by including the further step of introducing such species with or in addition to either or both of the carbon black manufacturing raw materials. Carbon black, for purposes of this invention, can be a multi-phase aggregate (also known as silicon treated carbon black, such as, for example, ECOBLAK™ material from Cabot Corporation) that contains at least one carbon phase and at least one metal-containing or silicon-containing species phase.

[0140] As noted above, the carbon black may be a rubber black, particularly a reinforcing grade carbon black or a semi-reinforcing grade carbon black.

[0141] Alternatively, the carbon black of the present invention can have functional or chemical groups (e.g., derived from ionic or nonionic small molecules or polymers) directly attached (e.g., covalently attached) to the carbon surface. Examples of functional groups that can be directly attached (e.g., covalently attached) to the surface of carbon black particles and methods for performing surface modification are described, for example, in U.S. Pat. No. 5,554,739, issued to Belmont on Sep. 10, 1996, and U.S. Pat. No. 5,922,118, issued to Johnson et al. on July 13, 1999, which are incorporated herein by reference in their entireties. As an example, a surface-modified carbon black that can be used herein is obtained by treating the carbon black with a diazonium salt, formed by the reaction of either sulfanilic acid or para-amino-benzoic acid (PABA) with HCl and NaNO2. For example, surface modification by the sulfanilic acid or para-amino-benzoic acid process using a diazonium salt results in carbon black with an effective amount of hydrophilic moieties on the carbon coating.

[0142] Carbon black can be surface modified according to US Pat. No. 8,975,316 to Belmont et al., the contents of which are incorporated herein by reference in their entirety.

[0143] Other techniques that can be used to provide functional groups attached to the surface of carbon black are described in U.S. Pat. No. 7,300,964, issued Nov. 27, 2007 to Niedermeier et al.

[0144] Oxidized (modified) carbon black can be prepared in a manner similar to that used for carbon black, for example, as described in U.S. Patent No. 7,922,805 issued to Kowalski et al. on April 12, 2011 and U.S. Patent No. 6,471,763 issued to Karl on October 29, 2002, which are incorporated herein by reference in their entirety. Oxidized carbon black is one that has been oxidized using an oxidizing agent to introduce ionic and / or ionizable groups onto the surface. Such particles may have a higher degree of oxygen-containing groups on the surface. Oxidizing agents include, but are not limited to, oxygen gas, ozone, peroxides such as hydrogen peroxide, persulfates including sodium persulfate and potassium persulfate, hypohalites such as sodium hypochlorite, oxidizing acids such as nitric acid, and transition metal-containing oxidizing agents such as permanganates, osmium tetroxide, chromium oxide, or cerium ammonium nitrate. Mixtures of oxidizing agents can also be used, particularly mixtures of gaseous oxidizing agents such as oxygen and ozone. Other surface modification methods, such as chlorination and sulfonylation, can also be used to introduce ionic or ionizable groups. Carbon black can be surface modified by any method known to those skilled in the art. For example, carbon black can be heat treated as described in U.S. Pat. No. 10,767,028, the entire contents of which are incorporated herein by reference.

[0145] Carbon black can be utilized in a variety of applications, such as as a reinforcing agent in rubber products, such as tire components.

[0146] Carbon black can be incorporated into rubber articles used, for example, in tire treads, particularly treads for passenger car, light vehicle, truck and bus tires, off-the-road ("OTR") tires, airplane tires, and the like; subtreads; wire skim; sidewalls; cushion gum for retread tires; and other tire applications.

[0147] In other applications, the particles can be used in industrial rubber articles such as engine mounts, hydro mounts, bridge bearings and isolators, tank tracks or treads, mining belts, hoses, gaskets, seals, blades, gap filling articles, bumpers, anti-vibration parts, etc.

[0148] Carbon black can be added in place of or in addition to the primary reinforcing agents for tire components and / or other industrial rubber end uses. Carbon black can be combined with natural and / or synthetic rubber in a suitable dry or wet mixing process based on an internal batch mixer, a continuous mixer or a roll mill.

[0149] Alternatively, the carbon black may be mixed into the rubber by a liquid masterbatch process. For example, a slurry containing the particles described herein may also be combined with an elastomer latex in a vat 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.

[0150] Carbon black can be introduced according to U.S. Patent No. 6,048,923, issued April 11, 2000 to Mabry et al., which is incorporated herein by reference in its entirety. For example, a method for preparing an elastomer masterbatch can include simultaneously feeding a particulate filler fluid and an elastomer latex fluid into a mixing zone of a coagulation reactor. The coagulation zone extends from the mixing zone and preferably has a gradually increasing cross-sectional area in a downstream direction from the inlet end to the discharge end. The elastomer latex can be either natural or synthetic, and the particulate filler comprises, consists essentially of, or consists of such materials. The particulate filler is preferably fed into the mixing zone as a continuous high-velocity jet of injected fluid, and the latex fluid is fed at a lower velocity. The velocity, flow rate and particle concentration of the particulate filler fluid are sufficient to cause high shear mixing of the latex fluid in at least an upstream portion of the coagulation zone and turbulent mixing of the mixture, thereby substantially completely coagulating the elastomeric latex with the particulate filler prior to the discharge end. Substantially complete coagulation can occur without the need for acid or salt coagulants. Additional elastomer can be added to the material exiting the discharge end of the coagulation reactor, as disclosed in U.S. Pat. No. 6,075,084, which is incorporated herein by reference in its entirety. The coagulate can then be fed to a dewatering extruder, as disclosed in U.S. Pat. No. 6,929,783, which is incorporated herein by reference in its entirety. Other examples of suitable masterbatch processes are disclosed in U.S. Pat. No. 6,929,783 to Chung et al., U.S. Patent Application Publication No. 2012 / 0264875(A1) to Berriot et al., U.S. Patent Application Publication No. 2003 / 0088006(A1) to Yanagisawa et al., and European Patent No. 1834985(B1) issued to Yamada et al.

[0151] Carbon black can be evaluated in suitable rubber formulations utilizing natural or synthetic rubbers. The appropriate amount of carbon black to be used can be determined by routine experimentation, calculation, and consideration of factors such as typical loadings of standard ASTM blacks in comparable manufacturing processes, parameters specific to the technology and / or equipment used, the presence or absence of other additives, and the desired properties of the final product.

[0152] The performance of carbon black as a reinforcing agent for rubber compounds can be evaluated, for example, by determining the performance of a rubber composition utilizing the particles compared to the performance of a comparative rubber composition that is similar in all respects except for the use of a carbon black grade suitable for a given application. In another approach, values ​​obtained for compositions prepared according to the present invention can be compared to values ​​known in the art that relate to desired parameters in a given application.

[0153] Suitable tests include green rubber tests, cure tests, and cured rubber tests. Among suitable green rubber tests, ASTM D4483 sets forth the test method for ML1+4 Mooney viscosity test at 100° C. Scorch time is measured according to ASTM D4818.

[0154] Cure curves are obtained by a rubber processing tester (RPA2000) at 0.5°, 100 cpm, and 150° C. (NR) to 160° C. (SBR) according to ASTM D5289.

[0155] The performance properties of the cured samples can be determined by a series of appropriate tests. Tensile strength, elongation at break, and stress at various strains (e.g., 100% and 300%) are all obtained by ASTM D412 Method A. Dynamic mechanical properties including storage modulus, loss modulus, and tan δ are obtained by strain sweep testing at 10 Hz, 60°C, and various strain amplitudes from 0.1% to 63%. Shore A hardness is measured according to ASTM D2240. Tear strength of die B cured rubber samples is measured according to ASTM D624.

[0156] The undispersed area is calculated by analyzing images obtained by a reflected mode optical microscope on a cut cross-sectional area of ​​the cured rubber compound according to various reported methods. Dispersion can also be expressed by the Z value (measured after reticulation according to the method described in the paper by S. Otto and Al in Kautschuk Gummi Kunststoffe, 58 Jahrgang, NR7-8 / 2005, entitled "New Reference value for the description of Filler Dispersion with the Dispergrader 1000NT"). Standard ISO 11345 specifies a visual method for the rapid and comparative evaluation of the degree of macrodispersion of carbon black and carbon black / silica in rubber.

[0157] Abrasion resistance is quantified as an index based on friction loss of cured rubber by Cabot Abrader (Lambourn type). Attractive abrasion results can indicate favorable wear characteristics. Good hysteresis results can be associated with lower rolling resistance (and correspondingly higher fuel economy) for automotive tire applications, reduced heat build-up, tire durability, tread life and casing life, fuel economy characteristics for automobiles, etc.

[0158] Iodine number (I2No.) is determined according to ASTM test procedure D1510. STSA (Statistical Thickness Surface Area) is determined according to ASTM test procedure D-5816 (measured by nitrogen adsorption). OAN is determined according to ASTM D2414. COAN is determined according to ASTM D3493 (e.g., D3493-20).

[0159] Unless otherwise specified, all material proportions stated as percentages herein are percentages by weight.

[0160] The present invention is further defined by the following examples, which are intended to be merely exemplary in nature.

[0161] The present invention includes the following aspects / embodiments / features in any order and / or in any combination. 1. A method for producing carbon black, comprising the steps of: electrically heating a carrier gas to form a heated carrier gas and causing pyrolysis of at least a portion of the carbon black feedstock to occur in a carbon black reactor by contacting the heated carrier gas, the carbon black feedstock comprising at least one first carbon black feedstock and at least one low yield carbon black feedstock; combining at least one first carbon black feedstock with the 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; downstream combining at least one low yield carbon black feedstock with the existing reaction stream to form carbon black, wherein the at least one low yield carbon black feedstock comprises at least 10 wt. % of the total carbon black feedstock; Recovering the carbon black in the reaction stream; and the first carbon black raw material is liquid at room temperature and pressure and has the following characteristics: Bureau of Mines Correlation Index (BMCI, U.S. Bureau of Mines Index) 100 or higher, Atomic H:C ratio of 1.23 or less, and Specific gravity over 1.02, and wherein the low yield carbon black feedstock has the following characteristics: Bureau of Mines Correlation Index (BMCI) less than 100, or Atomic H:C ratio greater than 1.23, or Specific gravity 1.02 or less, or It is a gas at room temperature and pressure, 1. A process according to claim 1, wherein the at least one low yield carbon black feedstock is present in an amount of from 10% to 90% by weight based on the total carbon black feedstock, and the at least one first carbon black feedstock is present in an amount of from 10% to 90% by weight based on the total carbon black feedstock. 2. A method for producing carbon black, comprising the steps of: electrically heating a carrier gas to form a heated carrier gas and causing pyrolysis of at least a portion of the carbon black feedstock to occur in a carbon black reactor by contacting the heated carrier gas, the carbon black feedstock comprising at least one first carbon black feedstock and at least one low yield carbon black feedstock; combining at least one first carbon black feedstock and at least one low yield carbon black feedstock, either as a blend or as separate additions, with the heated carrier gas at or near the same location 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; Recovering the carbon black in the reaction stream; and the first carbon black raw material is liquid at room temperature and pressure and has the following characteristics: Bureau of Mines Correlation Index (BMCI, U.S. Bureau of Mines Index) 100 or higher, Atomic H:C ratio of 1.23 or less, and Specific gravity over 1.02, and wherein the low yield carbon black feedstock has the following characteristics: Bureau of Mines Correlation Index (BMCI) less than 100, or Atomic H:C ratio greater than 1.23, or Specific gravity 1.02 or less, or It is a gas at room temperature and pressure, 1. A process according to claim 1, wherein the at least one low yield carbon black feedstock is present in an amount of from 10% to 90% by weight based on the total carbon black feedstock, and the at least one first carbon black feedstock is present in an amount of from 10% to 90% by weight based on the total carbon black feedstock. 3. A method for producing carbon black, comprising the steps of: electrically heating the at least one first carbon black feedstock to form a reactive stream such that pyrolysis of at least a portion of the at least one first carbon black feedstock occurs in the carbon black reactor, wherein the at least one first carbon black feedstock comprises at least 10 wt. % of the total carbon black feedstock; downstream combining at least one low yield carbon black feedstock with the existing reaction stream to form carbon black, wherein the at least one low yield carbon black feedstock comprises at least 10 wt. % of the total carbon black feedstock; Recovering the carbon black in the reaction stream; and the first carbon black raw material is liquid at room temperature and pressure and has the following characteristics: Bureau of Mines Correlation Index (BMCI, U.S. Bureau of Mines Index) 100 or higher, Atomic H:C ratio of 1.23 or less, and Specific gravity over 1.02, and wherein the low yield carbon black feedstock has the following characteristics: Bureau of Mines Correlation Index (BMCI) less than 100, or Atomic H:C ratio greater than 1.23, or Specific gravity 1.02 or less, or It is a gas at room temperature and pressure, 1. A process according to claim 1, wherein the at least one low yield carbon black feedstock is present in an amount of from 10% to 90% by weight based on the total carbon black feedstock, and the at least one first carbon black feedstock is present in an amount of from 10% to 90% by weight based on the total carbon black feedstock. 4. The method of any preceding or following embodiment / feature / aspect, further comprising electrically heating the at least one low-yield carbon black feedstock. 5. The method of any preceding or following embodiment / feature / aspect, wherein electrically heating the at least one low-yield carbon black feedstock comprises heating the low-yield carbon black feedstock to a temperature of 600-800° C. 6. The method of any preceding or following embodiment / feature / aspect, further comprising electrically heating at least one of the at least one first carbon black feedstock and the at least one low-yield carbon black feedstock. 7. The method of any preceding or following embodiment / feature / aspect, wherein the electrically heating is accomplished by an arc. 8. The method of any preceding or following embodiment / feature / aspect, wherein the electrically heating is accomplished using a resistive or inductive based heating element. 9. The method of any preceding or following embodiment / feature / aspect, wherein the heating element is magnesium oxide or yttria stabilized zirconia. 10. The method of any preceding or following embodiment / feature / aspect, wherein the heated carrier gas has a temperature greater than 2000° C. 11. The method of any preceding or following embodiment / feature / aspect, wherein the electrically heating is accomplished by induction or microwave based methods that prevent direct contact between the electrodes and the carrier gas or the carbon black feedstock. 12. The method of any preceding or following embodiment / feature / aspect, wherein the electrically heating is accomplished by a plasma arc or a heating element in direct contact with the carbon black feedstock. 13. The low yield carbon black raw material is: a) its Bureau of Mines Correlation Index (BMCI) is less than 95; or b) is a gas at room temperature and pressure; or c) the atomic H:C ratio is greater than 1.3, or d) the specific gravity is 1.0 or less; The method of any preceding or following embodiment / feature / aspect, wherein the method is at least one of: 14. The method of any of the preceding claims, wherein the low yield carbon black feedstock has a specific gravity of less than 1.02. 15. The method of any preceding or following embodiment / feature / aspect, wherein the low yield carbon black feedstock comprises at least one of the following: vegetable oil or other plant-derived oil, bio-derived ethanol, plant or animal wax or resin, oil obtained from animal fat, algae oil, oil obtained from pyrolysis of sewage sludge or agricultural waste, by-product liquids from processing of biogenic materials, liquids produced by hydrothermal liquefaction of biomaterials, crude tall oil, tall oil rosin, tall oil pitch or tall oil fatty acids, oil obtained from recycled materials, oil obtained from pyrolysis of low quality, rejected or end of life tires, oil obtained from pyrolysis of discarded or recycled plastic or rubber products, oil obtained from pyrolysis of municipal solid waste, or oil obtained from pyrolysis of biomass, or any combination thereof. 16. The method of any preceding or following embodiment / feature / aspect, wherein the at least first carbon black feedstock comprises one or more of decant oil, slurry oil, coal tar, coal tar derivatives, ethylene cracker residue, or phenol cracker residue. 17. The method of any preceding or following embodiment / feature / aspect, wherein the first carbon black feedstock is a fraction obtained from distillation of tire pyrolysis oil. 18. The method of any preceding or following embodiment / feature / aspect, wherein the low yield carbon black feedstock is in the range of 50-90 wt.% of the total feedstock charged in the method. 19. The method of any preceding or following embodiment / feature / aspect, wherein the low yield carbon black feedstock is in the range of 60-90 wt.% of the total feedstock charged in the method. 20. The method of any preceding or following embodiment / feature / aspect, wherein a carbon black reactor has a first chamber where the electrically heated is performed, a throat downstream of the first chamber, a reaction chamber downstream of the throat, and a quench zone downstream of the reaction chamber, and wherein a first carbon black feedstock is injected into the throat and a low yield carbon black feedstock is injected after the throat. 21. The method of any preceding or following embodiment / feature / aspect, wherein the carbon black reactor comprises a second throat downstream of the reaction chamber and before the quench zone, and the low yield carbon black feedstock is injected into the second throat. 22. The method of any preceding or following embodiment / feature / aspect, wherein the at least one first carbon black feedstock is introduced into the carbon black reactor at a first location and at least one other location downstream of the first location. 23. The method of any preceding or following embodiment / feature / aspect, wherein the amount of the first carbon black feedstock introduced at the first location is greater than 50% of the total amount of the first carbon black feedstock. 24. The method of any preceding or following embodiment / feature / aspect, wherein the at least one low yield carbon black feedstock is introduced into the carbon black reactor in at least two separate locations, one of the separate locations being downstream of the other. 25. The method of any preceding or following embodiment / feature / aspect, wherein the at least one first carbon black feedstock is a blend comprising less than 50 wt.% of a low-yield carbon black feedstock, based on the total weight of the first carbon black feedstock. 26. The method of any preceding or following embodiment / feature / aspect, wherein the at least one first carbon black feedstock is a blend comprising less than 5 wt.% of a low yield carbon black feedstock, based on the total weight of the first carbon black feedstock. 27. The method of any preceding or following embodiment / feature / aspect, wherein the at least one low yield carbon black feedstock is a blend comprising less than 50 wt.% of a first carbon black feedstock, based on the total weight of the low yield carbon black feedstock. 28. The method of any preceding or following embodiment / feature / aspect, wherein the at least one low yield carbon black feedstock is a blend comprising less than 5 wt.% of a first carbon black feedstock, based on the total weight of the low yield carbon black feedstock. 29. The method of any preceding or following embodiment / feature / aspect, wherein the low yield carbon black feedstock has the BMCI of less than 100. 30. The method of any preceding or following embodiment / feature / aspect, wherein the low yield carbon black feedstock has an atomic H:C ratio of greater than 1.23. 31. The method of any preceding or following embodiment / feature / aspect, wherein the low yield carbon black feedstock is a gas at room temperature and pressure. 32. The method of any preceding or following embodiment / feature / aspect, wherein the recovered carbon black is N110, N121, N220, N231, N234, N299, N326, N330, N339, N347, N351, N358, N375, N539, N550, N650, N660, N683, N762, N765, N774, N787, or N990 grade carbon black. 33. A carbon black produced by the method described in any preceding or following embodiment / feature / aspect.

[0162] The present invention may include any combination of these various features or embodiments described above and / or below in any sentence and / or paragraph herein. Any combination of features disclosed herein is considered part of the present invention and no limitation is intended with respect to features that may be combined.

[0163] The applicants specifically incorporate the entire contents of all cited documents into this disclosure. Furthermore, when an amount, concentration, or other value or parameter is given as either a range, a preferred range, or a list of a preferred upper value and a preferred lower value, this should be understood to specifically disclose all ranges formed from any pair of any range upper limit or preferred value and any range lower limit or preferred value, regardless of whether the range is separately disclosed. When a range of numerical values ​​is described herein, unless otherwise stated, the range is intended to include its endpoints, as well as all integers and fractions within the range. The scope of the present invention is not intended to be limited to the specific values ​​recited when defining the range.

[0164] Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims and equivalents thereof.

Claims

1. 1. A method for producing carbon black, comprising the steps of: electrically heating a carrier gas to form a heated carrier gas and causing pyrolysis of at least a portion of the carbon black feedstock to occur in a carbon black reactor by contacting the heated carrier gas, the carbon black feedstock comprising at least one first carbon black feedstock and at least one low yield carbon black feedstock; combining the at least one first carbon black feedstock with the heated carrier gas to form a reaction stream, the at least one first carbon black feedstock comprising at least 10 wt.% of the total carbon black feedstock; downstream combining at least one low yield carbon black feedstock with said exiting reaction stream to form said carbon black, said at least one low yield carbon black feedstock comprising at least 10% by weight of the total carbon black feedstock; recovering the carbon black in the reaction stream; and the first carbon black raw material being liquid at room temperature and pressure and having the following characteristics: Bureau of Mines Correlation Index (BMCI) 100 or higher; an atomic H:C ratio of 1.23 or less; and Specific gravity over 1.02, and wherein the low yield carbon black feedstock has the following characteristics: Bureau of Mines Correlation Index (BMCI) less than 100, or an atomic H:C ratio of greater than 1.23, or Specific gravity 1.02 or less, or It is a gas at room temperature and pressure, the at least one low yield carbon black feedstock is present in an amount from 10% to 90% by weight, based on the total carbon black feedstock, and the at least one first carbon black feedstock is present in an amount from 10% to 90% by weight, based on the total carbon black feedstock.

2. 1. A method for producing carbon black, comprising the steps of: electrically heating a carrier gas to form a heated carrier gas and causing pyrolysis of at least a portion of the carbon black feedstock to occur in a carbon black reactor by contacting the heated carrier gas, the carbon black feedstock comprising at least one 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, either as a blend or as separate additions, with the heated carrier gas at or near the same location 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; recovering the carbon black in the reaction stream; and the first carbon black raw material being liquid at room temperature and pressure and having the following characteristics: Bureau of Mines Correlation Index (BMCI) 100 or higher, an atomic H:C ratio of 1.23 or less; and Specific gravity over 1.02, and wherein the low yield carbon black feedstock has the following characteristics: Bureau of Mines Correlation Index (BMCI) less than 100, or an atomic H:C ratio of greater than 1.23, or Specific gravity 1.02 or less, or It is a gas at room temperature and pressure, the at least one low yield carbon black feedstock is present in an amount from 10% to 90% by weight, based on the total carbon black feedstock, and the at least one first carbon black feedstock is present in an amount from 10% to 90% by weight, based on the total carbon black feedstock.

3. 1. A method for producing carbon black, comprising the steps of: 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; downstream combining at least one low yield carbon black feedstock with said exiting reaction stream to form said carbon black, said at least one low yield carbon black feedstock comprising at least 10% by weight of the total carbon black feedstock; recovering the carbon black in the reaction stream; and the first carbon black raw material being liquid at room temperature and pressure and having the following characteristics: Bureau of Mines Correlation Index (BMCI) 100 or higher, an atomic H:C ratio of 1.23 or less; and Specific gravity over 1.02, and wherein the low yield carbon black feedstock has the following characteristics: Bureau of Mines Correlation Index (BMCI) less than 100, or an atomic H:C ratio of greater than 1.23, or Specific gravity 1.02 or less, or It is a gas at room temperature and pressure, the at least one low yield carbon black feedstock is present in an amount from 10% to 90% by weight, based on the total carbon black feedstock, and the at least one first carbon black feedstock is present in an amount from 10% to 90% by weight, based on the total carbon black feedstock.

4. 4. The method of any one of claims 1 to 3, further comprising electrically heating the at least one low-yield carbon black feedstock.

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

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

7. The method of claim 1 or 2, wherein the electrically heating is accomplished by an arc.

8. The method of claim 1 or 2, wherein the electrically heating is accomplished using a resistance or induction based heating element.

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

10. The method of any one of claims 1 to 9, wherein the heated carrier gas has a temperature above 2000°C.

11. 4. The method of any one of claims 1 to 3, wherein the electrically heating is accomplished by an induction or microwave based method that prevents direct contact between electrodes and the carrier gas or the carbon black feedstock.

12. 4. The method of claim 3, wherein the electrically heating is accomplished by a plasma arc or a heating element in direct contact with the carbon black raw material.

13. 4. The method of claim 3, further comprising the step of: a) the Bureau of Mines Correlation Index (BMCI) is less than 95; or b) is said gas at room temperature and pressure; or c) the atomic H:C ratio is greater than 1.3, or d) the specific gravity is 1.0 or less; The method according to any one of claims 1 to 12, wherein the method is at least one of the following:

14. The method of any one of claims 1 to 13, wherein the low yield carbon black feedstock has the specific gravity of less than 1.

02.

15. 15. The method of any one of claims 1 to 14, wherein the low yield carbon black feedstock comprises at least one of the following: vegetable oil or other plant-derived oil, bio-derived ethanol, plant or animal wax or resin, oil obtained from animal fat, algae oil, oil obtained from pyrolysis of sewage sludge or agricultural waste, by-product liquids from the processing of biogenic materials, liquids produced by hydrothermal liquefaction of biomaterials, crude tall oil, tall oil rosin, tall oil pitch or tall oil fatty acids, oil obtained from recycled materials, oil obtained from pyrolysis of low quality, rejected or end of life tires, oil obtained from pyrolysis of discarded or recycled plastic or rubber products, oil obtained from pyrolysis of municipal solid waste, or oil obtained from pyrolysis of biomass, or any combination thereof.

16. 16. The method of any one of the preceding claims, wherein the at least a first carbon black feedstock comprises one or more of decant oil, slurry oil, coal tar, coal tar derivatives, ethylene cracker residue, or phenol cracker residue.

17. 17. The method of any one of claims 1 to 16, wherein the first carbon black feedstock is a fraction obtained from distillation of tire pyrolysis oil.

18. 18. The process according to any one of claims 1 to 17, wherein the low yield carbon black feedstock is in the range of 50 to 90% by weight of the total feedstock charged in the process.

19. 19. The process according to any one of claims 1 to 18, wherein the low yield carbon black feedstock is in the range of 60 to 90 wt% of the total feedstock charged in the process.

20. 20. The method of any one of claims 1 to 19, wherein the carbon black reactor comprises a first chamber in which the electrically heated step occurs, a throat downstream of the first chamber, a reaction chamber downstream of the throat, and a quench zone downstream of the reaction chamber, and wherein the first carbon black feedstock is injected into the throat and the low yield carbon black feedstock is injected after the throat.

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

22. 22. The method of any one of the preceding claims, wherein the at least one first carbon black feedstock is introduced into the carbon black reactor at a first location and at least one distinct location downstream of the first location.

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

24. 24. The process of any one of claims 1 to 23, wherein the at least one low yield carbon black feedstock is introduced into the carbon black reactor in at least two separate locations, one of the separate locations being downstream of the other.

25. 25. The method of any one of the preceding claims, wherein the at least one first carbon black feedstock is a blend comprising less than 50 wt.% of a non-high yield carbon black feedstock, based on the total weight of the first carbon black feedstock.

26. 26. The method of any one of the preceding claims, wherein the at least one first carbon black feedstock is a blend comprising less than 5 wt.% of a non-high yield carbon black feedstock, based on the total weight of the first carbon black feedstock.

27. 27. The method of any one of the preceding claims, wherein the at least one low yield carbon black feedstock is a blend comprising less than 50 wt.% of a high yield carbon black feedstock, based on the total weight of the low yield carbon black feedstock.

28. 28. The method of any one of the preceding claims, wherein the at least one low yield carbon black feedstock is a blend comprising less than 5 wt.% of a high yield carbon black feedstock, based on the total weight of the low yield carbon black feedstock.

29. 29. The method of any one of the preceding claims, wherein the low yield carbon black feedstock has the BMCI less than 100.

30. 30. The method of any one of the preceding claims, wherein the low yield carbon black feedstock has an atomic H:C ratio greater than 1.

23.

31. 31. The method of any one of claims 1 to 30, wherein the low yield carbon black feedstock is said gas at room temperature and pressure.

32. 32. The method of any one of claims 1 to 31, wherein the recovered carbon black is N110, N121, N220, N231, N234, N299, N326, N330, N339, N347, N351, N358, N375, N539, N550, N650, N660, N683, N762, N765, N774, N787, or N990 grade carbon black.

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