Plasma-assisted production of carbon black

Abstract

The present invention relates to the plasma assisted production of carbon black. In particular, the present invention relates to a method and reactor that allows the carbon black feedstock to be injected at multiple locations within the carbon black reactor to avoid droplets in the plasma zone.

Description

[Technical field]

[0001] The present invention relates to the plasma assisted production of carbon black. In particular, the present invention relates to a method and reactor that allows the carbon black feedstock to be injected at multiple locations within the carbon black reactor to avoid droplets in the plasma zone. [Background technology]

[0002] Carbon black has many applications, such as reinforcing or filler for the rubber and tire industry. In addition, carbon black is increasingly being used in other areas, such as colorants for copiers and copying toners. The various applications of carbon black require a range of carbon black characteristics, such as particle size, structure, yield, surface area and dirt.

[0003] Typically, the production of carbon black produces a significant amount of CO2 as a by-product. The challenge is to have a carbon black process in place that consistently produces carbon black with significantly reduced CO2 emissions. Setting up a process using only electrical energy sources could solve this problem using only green electricity.

[0004] Furthermore, the available raw materials are often limited by the presence of liquid droplets in the plasma zone, which can damage the inner lining of the reaction chamber, as their deposition on the walls can cause temperatures to exceed the melting point of the inner lining.

[0005] It is therefore an object of the present invention to provide a reactor and method for the production of carbon black that overcomes the above-mentioned drawbacks. Summary of the Invention

[0006] The purpose of this is to (a) injecting a plasma gas into a carbon black reactor; (b) subjecting a plasma gas to the plasma zone to obtain a product mixture comprising carbon black; (c) quenching the product mixture; (d) separating the carbon black from the product mixture, This can be achieved by a production process in which: (i) the plasma gas comprises or consists of a carbon black feedstock; (ii) the carbon black feedstock is injected into the plasma gas upstream of the plasma zone; (iii) the carbon black feedstock is injected into the plasma zone, but preferably after the region where the plasma is generated; and / or (iv) the carbon black feedstock is injected into the plasma gas downstream of the plasma zone.

[0007] Further provided is a reactor for producing carbon black having a flow path along a central longitudinal axis of the reactor, the reactor comprising: (A) a reaction chamber; (B) an injection means for supplying carbon black feedstock; and (C) means for generating a plasma within the reaction chamber, thereby forming a plasma zone; wherein (i) the injection means for supplying the carbon black feedstock is located upstream of the plasma zone, (ii) the injection means for supplying the carbon black feedstock is located in the plasma zone, but preferably after the region where the plasma is generated, and / or (iii) the injection means for supplying the carbon black feedstock is located downstream of the plasma zone, preferably immediately after the plasma zone.

[0008] Furthermore, the carbon black produced according to the method of the present invention is preferably provided by using a reactor according to the present invention.

[0009] The present invention also relates to the use of a minimum molar percentage of a plasma gas, a plasma gas having a critical temperature below the temperature of the gas, and / or a material having a critical temperature below the temperature of the gas (preferably a plasma gas having a critical temperature below the temperature of the gas) to prevent the formation of droplets in a reactor (or condensation in a reactor) in carbon black production, where the plasma gas and the carbon black feedstock are mixed prior to subjecting the gases to the plasma zone, and the minimum molar percentage is based on the total molar amount of the plasma gas including the carbon black feedstock, and is less than x dilutant Greater than x dilutant is calculated according to formula (V), formula (IX) and / or formula (XVII).

[0010]

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[0011] In the formula, x dilutant is the dilution factor, P [Pa] is the pressure of the plasma gas mixture, P0 [Pa] is the atmospheric pressure, which is set to 101325 Pa, and Δ vap H m where [J / mol] is the standard molar enthalpy of vaporization of the carbon black raw material (e.g., calculated according to formula (I)), R [J / mol / K] is the universal gas constant, i.e., 8.314463 J / mol / K, T [K] is the system temperature or temperature of the plasma gas mixture, and T b [K] is the standard boiling point (atmospheric pressure P0 = 101325 Pa) of the carbon black raw material.

[0012]

number

[0013] In the formula, x dilutant is the dilution degree, P [Pa] is the pressure of the plasma gas mixture, i represents each compound in the carbon black feedstock, and Σ i=1 Nis the sum of i=1 to N, i is the compound index of the compound in the carbon black raw material, and x i vapour is the mole percentage of each compound in the carbon black feedstock, and P i s [Pa] is the vapor pressure of each compound i in the carbon black raw material at the plasma gas temperature T [K], and P i s is calculated according to formula (X).

[0014]

number

[0015] P0 [Pa] is atmospheric pressure, set to 101325 Pa, Δ vap H m,i [J / mol] is the standard molar enthalpy of vaporization of each compound in the carbon black feedstock (e.g., calculated according to formula (I)), R [J / mol / K] is the universal gas constant, i.e., 8.314463 J / mol / K, T [K] is the system temperature or temperature of the plasma gas mixture, and T b,i [K] is the standard boiling point (atmospheric pressure P0 = 101325 Pa) of each compound in the carbon black raw material.

[0016]

number

[0017] In the formula, x dilutant is the dilution factor, P [Pa] is the pressure of the plasma gas mixture, i represents each sample of carbon black raw material, and Σ i=1 10 is the sum of i=1 to N, where i is the compound index of the carbon black raw material sample, and x pseudo,i vapour is the mole percentage of each sample of carbon black raw material, and P pseudo,i s[Pa] is the vapor pressure of each sample i of the carbon black raw material at the plasma gas temperature T [K], and P pseudo,i s is calculated according to formula (XVIII).

[0018]

number

[0019] P0 [Pa] is atmospheric pressure, set to 101325 Pa, Δ vap H m,i [J / mol] is the standard molar enthalpy of vaporization of each sample of carbon black raw material (e.g., calculated according to equation (XIII)), R [J / mol / K] is the universal gas constant, i.e., 8.314463 J / mol / K, T [K] is the system temperature or temperature of the plasma gas mixture, and T b,i [K] is the standard (atmospheric pressure P0 = 101325 Pa) boiling point of each sample of carbon black raw material.

[0020] Preferably, the mole percentage of the plasma gas is x dilutant Super and (x dilutant +20 mol%), and more preferably the mole percentage of the plasma gas is between (x dilutant +1mol%) and (x dilutant +15 mol%), and even more preferably the mole percentage of the plasma gas is between (x dilutant +3mol%) and (x dilutant +12 mol%), and most preferably the mole percentage of the plasma gas is between (x dilutant +5mol%) and (x dilutant +10mol%).

[0021] The present invention further relates to the use of at least two injection means for carbon black feedstock in a reactor for producing carbon black having a flow path along a central longitudinal axis of the reactor, to prevent the formation of droplets in the reactor (or condensation in the reactor), the reactor comprising: (A) a reaction chamber; (B) injection means for supplying the carbon black feedstock; and (C) means for generating a plasma in the reaction chamber, thereby forming a plasma zone, wherein: (i) the injection means for supplying the carbon black feedstock are located upstream of the plasma zone; (ii) the injection means for supplying the carbon black feedstock are located in the plasma zone, but preferably after the region where the plasma is generated; and / or (iii) the injection means for supplying the carbon black feedstock are located downstream of the plasma zone, preferably immediately after the plasma zone. [Brief description of the drawings]

[0022] [Figure 1] Reactor for carbon black production. [Diagram 2] Section of a swirl element in the xz plane. [Diagram 3] Section of a pivot element in the xy plane. [Figure 4] A section of tubular conduit including a feed lance and a swivel element connected to an exterior surface of the feed lance. [Diagram 5] A section of tubular conduit including an inlet funnel, a feed lance, and a swirl element connected to an exterior surface of the feed lance. [Figure 6] A section of a tubular conduit including a feed lance and a swivel element connected to an inner surface of the tubular conduit. [Figure 7] A section of a tubular conduit including an inlet funnel, a feed lance, and a swirl element connected to an inner surface of the tubular conduit. [Figure 8] A section of a swivel element having two regions of constant pitch and a smooth connection. [Figure 9] A section of a pivoting element having two regions of constant pitch and a sharp connection. [Figure 10] A section of a pivoting element having a continuously increasing or decreasing pitch. [Figure 11] A section of the feed lance containing three pivoting elements with different alignments. [Figure 12] A section of the feed lance containing three pivoting elements with different alignments. [Figure 13] FIG. 2 is a multi-view projection of a swivel element having one vane attached to the outer surface of a feed lance. [Figure 14] Section of the swivel element without the feed lance. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0023] As mentioned above, the present invention relates to a carbon black reactor and a method for producing carbon black, preferably using the carbon black reactor described above. The present invention will now be described with reference to the accompanying drawings, which do not limit the scope and area of ​​the present invention.

[0024] It should be noted that as used in this specification and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to "a feedstock" includes mixtures of two or more such feedstocks, and the like.

[0025] "Longitudinal axis" refers to an axis extending in the direction of the length (or longitude) of an object. "Lateral axis" refers to an axis extending in the direction of the width of an object. "Transverse axis" refers to an axis extending in the direction of the height of an object. The axes are disposed perpendicular to one another. Thus, the term "central longitudinal axis of the reactor" refers to the working axis extending in the direction of the length of the carbon black reactor. The reaction chamber and the tubular conduit are disposed along said central longitudinal axis of the reactor. The longitudinal axis of the tubular conduit and the central longitudinal axis of the reactor may be coaxial.

[0026] The term "swirl" refers to a gas flow having a spin in or along a particular direction, for example along an axis. The terms swirl and spin can be used synonymously. Thus, a swirling gas flow is a directional rotational motion along an axis. The swirling gas flow according to the present invention has a spin along the central longitudinal axis of the reactor. It is clear that the swirl or spin of the gas can rotate to the left or right in the flow direction. Depending on the design of the swirl element, the rotation can be adjusted. However, it is desirable that the swirl element and / or vanes are designed such that the flow rotation is either to the left or right and propagates in the flow direction. The rotation axis of the gas is generally approximately coaxial or coaxial with the central longitudinal axis of the reactor or the central longitudinal axis of the tubular conduit.

[0027] The gas stream can be swirled by passing it through a swirling element that can cause the gas stream to swirl or spin. For example, the swirling element provides a means to induce the aforementioned directional rotational motion along the axis of the gas stream. In the present invention, the gas is a plasma gas or a feedstock. Swirling elements are described in detail below.

[0028] Diameter always refers to the inside diameter of an object unless otherwise specified, for example, the diameter of a tubular conduit refers to the inside diameter of the tubular conduit.

[0029] The present invention relates to (a) injecting a plasma gas into a carbon black reactor; (b) subjecting a plasma gas to a plasma zone (or plasma torch) to obtain a product mixture comprising carbon black; (c) quenching the product mixture; (d) separating the carbon black from the product mixture; wherein (i) the plasma gas comprises or consists of a carbon black feedstock; (ii) the carbon black feedstock is injected into the plasma gas upstream of the plasma zone; (iii) the carbon black feedstock is injected into the plasma zone, but preferably after the region where the plasma is generated; and / or (iv) the carbon black feedstock is injected into the plasma gas downstream of the plasma zone.

[0030] It is therefore possible to provide the carbon black feedstock at multiple locations in the carbon black reactor. It is important to avoid the formation of droplets in the plasma zone of the reaction chamber. The amount of carbon black feedstock (feedstock, or raw material for carbon black) present in the plasma gas can affect the droplet formation in the plasma zone. Thus, the amount of carbon black feedstock present upstream of the plasma zone can be reduced by introducing the feedstock downstream of the region where the plasma is generated, e.g., in the plasma zone or downstream of the plasma zone. The region where the plasma is generated means the region where the excitation of the plasma gas takes place, e.g., the region where the microwave radiation excites the plasma gas.

[0031] The product mixture refers to a mixture that includes the produced carbon black. In addition, plasma gases and additional pyrolysis products may be present.

[0032] The plasma zone is the area in the reaction chamber where the plasma is present or where the plasma torch is present. The plasma zone can also be called plasma column, plasma torch, plasma flame, plasma jet or plasma. The size of the plasma zone can be selected as required. Said size can be adapted, for example, by the gas flow (plasma gas flow) and the energy input of the plasma generator. In general, the plasma zone starts from the position where the plasma gas is excited and extends downstream of the reaction chamber or reactor. Therefore, if the carbon black feedstock is injected into the plasma zone, it is particularly preferred that the injection is performed after the area where the plasma is generated or after the area where the plasma gas is excited.

[0033] The feedstock can be introduced into the reaction chamber at one of the above mentioned locations. However, it may be desirable to use two or more locations to introduce the feedstock. For example, a first carbon black feedstock is introduced upstream of the plasma zone and a second carbon black feedstock is introduced downstream of the region where the plasma is generated, preferably after the region where the plasma gas is excited.

[0034] The first carbon black feedstock may be injected into the plasma gas prior to subjecting the plasma gas to the plasma zone, and the second carbon black feedstock is injected into the plasma zone, but preferably after the region where the plasma is generated.

[0035] The first carbon black feedstock may be injected into the plasma gas prior to subjecting the plasma gas to the plasma zone, and the second carbon black feedstock is injected immediately after the plasma zone.

[0036] The first and second carbon black feedstocks are preferably the same carbon black feedstock, however, the carbon black feedstocks can be different from each other.

[0037] If the plasma gas is swirled before entering the reaction chamber, the feedstock is preferably introduced downstream of the plasma zone, i.e., just behind the plasma zone. It is believed that swirling the plasma gas modifies the plasma morphology and creates a backflow in the center of the plasma, so that the carbon black feedstock injected just behind the plasma is entrained into the plasma.

[0038] The feedstock injected into the plasma gas upstream of the plasma zone can be either injected by a feed lance that is coaxial with the central longitudinal axis of the reactor or by a nozzle positioned perpendicular to the central longitudinal axis of the reactor. The perpendicular nozzles can be positioned circumferentially within the reaction chamber. This configuration can be used to induce swirl of the plasma gas (plasma gas mixture).

[0039] The means for generating plasma is not limited to a specific plasma generating means, as any suitable device can be used. The plasma can be generated in response to excitation of the plasma gas by microwave energy, the plasma can be generated in response to excitation of the plasma gas by an electric arc, the plasma can be generated in response to excitation of the plasma gas by a corona discharge, the plasma can be generated in response to excitation of the plasma gas by a dielectric barrier discharge (DBD), and / or the plasma can be generated in response to excitation of the plasma gas by radio frequency energy, preferably the plasma can be generated in response to excitation of the plasma gas by microwave energy. The frequency of the microwave energy can be 500 MHz to 100 GHz, preferably 800 MHz to 10 GHz, more preferably 900 MHz to 5 GHz, and most preferably 900 MHz to 3 GHz.

[0040] The plasma gas can be preheated before subjecting the gas to the plasma zone (or reaction chamber), preferably the plasma gas is preheated to a temperature of 100-1600°C, e.g. 300-1400°C, 400-1200°C, 500-1000°C, 600-1500°C, 100-300°C, 200-400°C, 300-500°C, 400-600°C, 1000-1500°C, or 700-900°C. Preheating should be done by electrical means. Combustion of fuel should be avoided so that CO2 emissions can be reduced. Similarly, the carbon black feedstock can be preheated to a temperature of 100-600°C, e.g. 150-500°C, or 200-400°C. The energy source for preheating the carbon black feedstock and / or the plasma gas should be electrical energy, preferably electrical energy generated from a renewable energy source.

[0041] The plasma gas containing the carbon black raw material can have a temperature of (i) 260 to 920 K, preferably 269 to 700 K, (ii) 290 to 340 K, (iii) 340 to 390 K, (iv) 390 to 440 K, (v) 440 to 490 K, (vi) 490 to 540 K, (vii) 540 to 590 K, (viii) 590 to 640 K, (ix) 640 to 690 K, or (x) 690 to 740 K.

[0042] The temperature of the plasma gases can be important so that droplet formation of the carbon black feedstock can be avoided. Cold gases have a negative effect on droplet formation in the reaction chamber.

[0043] The plasma gas may include or be hydrogen (H2) and / or water (H2O) and / or the plasma gas may include or be a carbon black feedstock. Thus, the plasma gas may be a carbon black feedstock. The plasma gas and the carbon black feedstock should be mixed before subjecting the gas to the plasma zone. The plasma gas may also include or be N2, CO2 and / or air. However, hydrogen (H2) and / or water (H2O) are preferred plasma gases, with hydrogen being the most preferred plasma gas. It is particularly preferred that the plasma gas is a material that has a critical temperature below the temperature of the gas. Gas generally refers to the plasma gas mixture present upstream of the plasma zone.

[0044] Carbon black is formed by subjecting a carbon black feedstock to a plasma, i.e., plasma-assisted carbon black production. After the carbon black is formed, the product mixture containing the carbon black is quenched. Quenching the product mixture reduces the temperature of the product mixture. Additionally, product properties can be controlled by quenching the product mixture. Cooling media such as water, heat exchangers, and / or quench boilers can be used.

[0045] Depending on the temperature of the gas (plasma gas, plasma gas mixture), a minimum dilution of materials with a critical temperature below the temperature of the gas may be necessary to prevent droplets (or prevent condensation) in or before the plasma zone. This is particularly important when carbon black raw materials with high boiling points or high critical temperatures are used. Such carbon black raw materials tend to form droplets (condensate or simply turn into a liquid phase) in or near the plasma zone, which can damage the reactor, the reaction chamber, and / or the inner lining of the reaction chamber.

[0046] The material having a critical temperature below the temperature of the gas should be present in the plasma gas containing the carbon black raw material in a molar ratio such that the carbon black raw material does not form droplets (or condense or is not in the liquid phase) in the carbon black reactor prior to subjecting the gas to the plasma zone.

[0047] A material with a critical temperature below the temperature of the gas does not exist as a liquid, i.e., does not have a vapor pressure at the temperature of the gas. Gas refers to the plasma gas, including the carbon black raw material, especially that present upstream of the plasma zone. The critical temperature of a substance is the temperature at which and above which the vapor of the material (or substance) cannot be liquefied, no matter how much pressure is applied. At low pressures the material is in the gas phase, and at high pressures the material is in the supercritical fluid phase. The critical temperatures of materials or substances are disclosed in Landolt Bernstein, Numbers and Functions, 6th Edition, Vol. 2 / 1, Table 21116, p. 328, Berlin-Heidelberg-New York: Springer-Verlag, 1971, or in the NIST Chemistry Webbook (https: / / WebBook.nist.gov / Chemistry / name-ser / ).

[0048] It is particularly desirable for the plasma gas to be or include a material having a critical temperature below the temperature of the gas. For example, hydrogen has a critical temperature of 33.18K. Hydrogen is a suitable plasma gas since the temperature of the plasma gas (including the carbon black feedstock) is typically greater than 10°C, e.g., greater than 18°C, greater than 30°C, or greater than 100°C. Methane, which can be used to produce carbon black, is considered a feedstock material and also has a critical temperature of 190.56K, so if the gas (or plasma gas or plasma gas mixture including the carbon black feedstock) has a temperature greater than 190.56K, then methane is a material having a critical temperature below the temperature of the gas.

[0049] It is particularly desirable to mix the plasma gas with the carbon black feedstock prior to subjecting the gas to the plasma zone in a molar ratio (plasma gas-carbon black mixture with carbon black feedstock) such that the carbon black feedstock does not form droplets in the carbon black reactor. The molar ratio can be calculated as described below.

[0050] Additionally, it is particularly desirable for the material having a critical temperature below the temperature of the gas (i.e., of the system, of the gas mixture, and / or of the plasma gas mixture) to be present in the plasma gas containing the carbon black raw material (the plasma gas containing the carbon black raw material-carbon black mixture) in a molar ratio such that the carbon black raw material does not form droplets in the carbon black reactor prior to subjecting the gas to the plasma zone. The molar ratio can be calculated as described below.

[0051] If it is desired to use a larger amount of feedstock, additionally, (iii) a carbon black feedstock (second carbon black feedstock) can be injected into the plasma zone, but preferably after the area where the plasma is generated, and / or (iv) the carbon black feedstock is injected downstream of the plasma gas and / or rearward of the plasma zone, where rear can mean 1 to 50 mm behind the plasma zone or behind the plasma torch.

[0052] The desired molar ratio of the plasma gas (without feedstock), or material having a critical temperature below the temperature of the gas (i.e., of the system, of the gas mixture, and / or of the plasma gas mixture) can be calculated using the following formulas (V), (VI), (IX), and / or (XVII): In particular, the minimum molar percentage of the plasma gas, the plasma gas having a critical temperature below the temperature of the gas, and / or material having a critical temperature below the temperature of the gas (preferably the plasma gas having a critical temperature below the temperature of the gas) is calculated using the formulas above.

[0053] In the following, the required dilution or degree of dilution x of the carbon black feedstock and / or material having a critical temperature higher than the temperature of the gas (i.e., of the system, of the gas mixture, and / or of the plasma gas mixture) is dilutant We explain the calculation of the required (or minimum) dilution x dilutant is expressed as the molar percentage of the material having a critical temperature below the temperature of the plasma gas and / or gas (i.e., of the system, of the gas mixture, and / or of the plasma gas mixture). In other words, in general, a certain percentage of material having a critical temperature below the temperature of the gas is required to avoid condensation of material having a critical temperature above the temperature of the gas. The material having a critical temperature below the temperature of the gas may be the plasma gas and / or partially the carbon black feedstock. The material having a critical temperature above the temperature of the gas may be the carbon black feedstock (first carbon black feedstock).

[0054] x dilutant In the formula for the calculation of the pressure P [Pa] and the temperature T can be selected as necessary. For example, it is desirable to carry out the method at 1 atm or 101325 Pa and 300 K.

[0055] If the temperature-dependent vapor pressure is not available for any pure compound (e.g. carbon black raw material), the vapor pressure can be estimated starting from the standard boiling point. For compounds, a standard entropy of vaporization of 88 J / mol / K is used according to the Pictet-Trouton rule. For all formulas, it is particularly preferred that 88 J / mol / K is used for the standard entropy of vaporization (molar entropy of vaporization P=101325 Pa). Alternatively, the Cedenberg equation can be used. The term "standard" refers to the respective value at 1 atm, i.e. 101325 Pa. If the pressure is not explicitly mentioned for the calculation, it is preferable to use 1 atm. If specific units (e.g. temperature and pressure) are indicated, it is possible to convert the units to the appropriate units.

[0056] Starting from the standard boiling point and molar entropy of vaporization, Δ vap H m We obtain the standard molar enthalpy of vaporization expressed as:

[0057]

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[0058] In the formula, Δ vap H m [J / mol] is the standard molar enthalpy of vaporization of the carbon black raw material, T b [K] is the standard boiling point, and Δ vap S m [J / K / mol] is the standard molar entropy of vaporization of the carbon black feedstock, which refers to the carbon black feedstock having a critical temperature above the temperature of the gas.

[0059] The differential equation for the boiling curve can be derived from the phase equilibrium conditions according to the Clausius-Clapyron equation:

[0060]

number

[0061] where dP / dT is the slope of the tangent to the coexisting vapor pressure curve at any point, and (V m vapour -V m liquid ) is the volume change at the phase transition between gas and liquid, and Δ vap H m [J / mol] is the standard molar enthalpy of vaporization (e.g., calculated according to equation (I)).

[0062] Assuming a constant enthalpy of vaporization, ignoring the liquid volume relative to the molar vapor volume, and assuming the ideal gas law for the molar volume of the vapor phase, we obtain the vapor pressure equation:

[0063]

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[0064] In the formula, P s [Pa] is the vapor pressure of the carbon black raw material at the plasma gas temperature T [K], P0 [Pa] is the atmospheric pressure, set at 101325 Pa, R is the universal gas constant, i.e., 8.314463 J / mol / K, T [K] is the system temperature or the temperature of the plasma gas, T b [K] is the normal boiling point of the carbon black feedstock, which refers to the carbon black feedstock that has a critical temperature above the temperature of the gas.

[0065] Dilution in percentage x dilutant is given by the following equation:

[0066]

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[0067] In the formula, x dilutant is the dilution factor, and P s [Pa] is the vapor pressure of the carbon black raw material at the plasma gas temperature T [K], and P0 [Pa] is the atmospheric pressure, which is set to 101325 Pa.

[0068] Combining equations (III) and (IV) gives equation (V): Equations (IV), (V) and (VI) have the condition that the minimum value is 0 (zero) since a negative value for the molar ratio simply means that no dilution is required, i.e. the molar ratio is zero (denoted as max(,0)).

[0069]

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[0070] In the formula, x dilutant is the dilution factor, P [Pa] is the pressure of the plasma gas mixture, P0 [Pa] is the atmospheric pressure, which is set to 101325 Pa, and Δ vap H m [J / mol] is the standard molar enthalpy of vaporization of the carbon black raw material (e.g., calculated according to formula (I)), R [J / mol / K] is the universal gas constant, i.e., 8.314463 J / mol / K, T [K] is the system temperature or temperature of the plasma gas mixture, and T b [K] is the standard boiling point of the carbon black raw material (atmospheric pressure P0 = 101325 Pa). The carbon black raw material refers to a carbon black raw material having a critical temperature higher than the gas temperature.

[0071] Or, x dilutant Under conditions where M is greater than 0 (which means that the feedstock and plasma gas (or material with a critical temperature below the temperature of the gas) are selected such that a minimum molar ratio of plasma gas (or material with a critical temperature below the temperature of the gas) is required), formula (VI) can be used.

[0072]

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[0073] In the formula, x dilutant is the dilution factor, P [Pa] is the pressure of the plasma gas mixture, P0 [Pa] is the atmospheric pressure, which is set to 101325 Pa, and Δ vap H m [J / mol] is the standard molar enthalpy of vaporization of the carbon black raw material (e.g., calculated according to formula (I)), R [J / mol / K] is the universal gas constant, i.e., 8.314463 J / mol / K, T [K] is the system temperature or temperature of the plasma gas mixture, and T b[K] is the standard boiling point of the carbon black raw material (atmospheric pressure P0 = 101325 Pa). The carbon black raw material refers to a carbon black raw material having a critical temperature higher than the gas temperature.

[0074] dilution x dilutant refers to the mole percent of the plasma gas, the mole percent of the plasma gas that has a critical temperature below the temperature of the gas, and / or the mole percent of the material that has a critical temperature below the temperature of the gas. dilutant refers to the mole percentage of the plasma gas having a critical temperature below the temperature of the gas and / or the mole percentage of the material having a critical temperature below the temperature of the gas. More preferably, the dilution degree x dilutant refers to the mole percent of the plasma gas that has a critical temperature below the temperature of the gas, and the mole percent of the material that has a critical temperature below the temperature of the gas. Most preferably, the dilution degree x dilutant refers to the mole percent of the material that has a critical temperature below the temperature of the gas.

[0075] In Tables 1 and 2, dilution factor x dilutant x dilutant was calculated assuming that the minimum value of is zero (denoted as max(,0)). Thus, the values ​​in these tables indicate the mole percentage of plasma gas and / or material that has a critical temperature below the temperature of the gas to avoid condensation (no droplets). C3-C23 in Table 1 refer to aliphatic hydrocarbons with the respective carbon numbers. For example, C3 represents C3H8. Δ vap H m =T b Δ vap S m The standard molar entropy of evaporation, Δ, is calculated using vap H mThe standard molar entropy of evaporation of 88 J / mol / K was used as the percentage. The percentage is calculated using formula (V). Each measurement or calculation refers to a specific gas temperature such as 268.04 K, 300 K, 350 K, 400 K, 450 K, 500 K, 550 K, 600 K, 650 K, and 700 K, as shown in the table. In the formula, the temperature can be selected as required. The system pressure or pressure of the gas / plasma gas mixture P [Pa] is 101325 Pa. Table 2 refers to the aromatic feedstock.

[0076] The temperature of the plasma gas, T, for calculations including the carbon black feedstock can be set to the system temperature minus 10 K or 5 K so that the resulting mole percentages account for deviations in the temperature of the gas. This can be done for T in all equations. However, T should be the temperature of the plasma gas including the carbon black feedstock.

[0077] Also, the calculated mole percentages are with respect to the plasma gas containing the carbon black feedstock that is present upstream of the plasma zone. The additional feedstock can be injected in any suitable amount directly into the plasma zone or after the plasma zone.

[0078] Table 1: The molar percentage required to avoid condensation of plasma gases and / or materials that have a critical temperature below the temperature of the gas, calculated taking into account different gas temperatures.

[0079] [Table 1]

[0080] Table 2: Molar percentages required to avoid condensation of plasma gases and / or materials with critical temperatures below that of the gas, calculated taking into account different gas temperatures.

[0081] [Table 2]

[0082] Equations (V) and (VI) are particularly useful for carbon black feedstocks that include one carbon black feedstock with a critical temperature above the temperature of the gas. For example, the carbon black feedstock includes some hydrocarbons with critical temperatures below the temperature of the gas and one hydrocarbon with a critical temperature above the temperature of the gas. Calculations according to Equations (V), (VI), (IX) and (XVII) desirably take into account the carbon black feedstock with a critical temperature above the temperature of the gas.

[0083] The plasma gas and carbon black feedstock should be mixed prior to subjecting the gases to the plasma zone, where the mole percent of the plasma gas, or the mole percent of the material having a critical temperature below the temperature of the gas (preferably the mole percent of the material having a critical temperature below the temperature of the gas), based on the total molar amount of the plasma gas including the carbon black feedstock, is greater than or equal to x. dilutant greater than, where x dilutant can be calculated according to formula (V).

[0084]

number

[0085] In the formula, x dilutant is the dilution factor, P [Pa] is the pressure of the plasma gas mixture, P0 [Pa] is the atmospheric pressure, which is set to 101325 Pa, and Δ vap H m [J / mol] is the standard molar enthalpy of vaporization of the carbon black raw material (e.g., calculated according to formula (I)), R [J / mol / K] is the universal gas constant, i.e., 8.314463 J / mol / K, T [K] is the system temperature or temperature of the plasma gas mixture, and T b [K] is the standard (atmospheric pressure P0=101325 Pa) boiling point of the carbon black raw material, and preferably the mole percentage of the plasma gas is x dilutant Super and (xdilutant +20 mol%), and more preferably the mole percentage of the plasma gas is between (x dilutant +1mol%) and (x dilutant +15 mol%), and even more preferably the mole percentage of the plasma gas is between (x dilutant +3mol%) and (x dilutant +12 mol%), and most preferably the mole percentage of the plasma gas is between (x dilutant +5mol%) and (x dilutant +10mol%). The mole percentage of the plasma gas is at least x dilutant (or x dilutant and more preferably the mole percent of the plasma gas is at least (x dilutant +1 mol%), and even more preferably the mole percentage of the plasma gas is at least (x dilutant +3 mol%), and most preferably the mole percentage of the plasma gas is at least (x dilutant +5mol%).

[0086] dilution x dilutant refers to the mole percent of the plasma gas, the mole percent of the plasma gas that has a critical temperature below the temperature of the gas, and / or the mole percent of the material that has a critical temperature below the temperature of the gas. dilutant refers to the mole percentage of the plasma gas having a critical temperature below the temperature of the gas and / or the mole percentage of the material having a critical temperature below the temperature of the gas. More preferably, the dilution degree x dilutant refers to the mole percent of the plasma gas that has a critical temperature below the temperature of the gas, and the mole percent of the material that has a critical temperature below the temperature of the gas. Most preferably, the dilution degree x dilutant refers to the mole percent of the material that has a critical temperature below the temperature of the gas.

[0087] The molar percentage refers to said carbon black raw material before subjecting the gas to the plasma zone. Generally, the plasma gas is a material, such as hydrogen, that has a critical temperature below the temperature of the gas. Thus, utilizing an optimal molar ratio of plasma gas (or material that has a critical temperature below the temperature of the gas) to carbon black raw material, there is no formation of droplets in or before the plasma zone. Additionally, the highest possible percentage of carbon black raw material is beneficial to the properties of the carbon black produced.

[0088] This allows precise adjustment of the content of the raw material present in the plasma gas. It should be noted that the raw material injected directly into the plasma zone or downstream of the plasma zone can be injected in any suitable amount. The raw material can be the second carbon black raw material. Thus, the first carbon black raw material is the raw material injected before the plasma zone.

[0089] The plasma gas and the carbon black feedstock (plasma gas and carbon black mixture) can be mixed prior to subjecting the gases to the plasma zone, wherein the molar percentage of the plasma gas and / or material having a critical temperature below the temperature of the gas (atmospheric pressure 101325 Pa), based on the total molar amount of the plasma gas including the carbon black feedstock, is (i) 1 to 20 mol % when the normal boiling point and / or final normal boiling point of the carbon black raw material is 270 to 300 K and the temperature of the gas mixture is 250 to 290 K; (ii) 30 to 95 mol % when the normal boiling point of the carbon black raw material is more than 300 to 350 K and the temperature of the gas mixture is 270 to 300 K; (iii) 50 to 80 mol % when the normal boiling point and / or final normal boiling point of the carbon black raw material is more than 350 to 400 K and the temperature of the gas mixture is 340 to 360 K; (iv) 50 to 75 mol% when the normal boiling point and / or final normal boiling point of the carbon black raw material is more than 400 to 450 K and the temperature of the gas mixture is 390 to 420 K; (v) 40 to 65 mol % when the normal boiling point and / or final normal boiling point of the carbon black raw material is more than 450 to 500 K and the temperature of the gas mixture is 440 to 460 K; (vi) 20 to 65 mol % when the normal boiling point and / or final normal boiling point of the carbon black raw material is more than 500 to 550 K and the temperature of the gas mixture is 490 to 520 K; (vii) 20 to 55 mol % when the normal boiling point and / or final normal boiling point of the carbon black feedstock is greater than 550 to 610 K and the temperature of the gas mixture is between 540 and 570 K; or (viii) 30 to 65 mol % when the normal boiling point and / or final normal boiling point of the carbon black raw material is greater than 610 to 670 K and the temperature of the gas mixture is 590 to 630 K. The plasma gas preferably has a critical temperature of less than 270 K.

[0090] The plasma gas can consist of a carbon black feedstock, preferably a carbon black feedstock having a critical temperature below the temperature of the gas. Furthermore, the feedstock can be a composition that includes many different hydrocarbons. Each hydrocarbon can have a different boiling point and / or critical temperature. For example, the plasma gas can include 40% by weight H2, 20% by weight C3H8, and 40% by weight of a hydrocarbon having a critical temperature above the temperature of the gas.

[0091] Generally, the plasma gas containing the carbon black raw material is heated (at atmospheric pressure of 101325 Pa) to a temperature of 100° C. prior to subjecting the gas to the plasma zone. (i) when the final normal boiling point of the carbon black raw material is between 270 and 300 K and the temperature of the gas mixture is between 250 and 290 K, it contains between 1 mol % and 20 mol % of a material having a critical temperature lower than the temperature of the gas; (ii) when the final normal boiling point of the carbon black raw material is greater than 300 to 350 K and the temperature of the gas mixture is between 270 and 290 K, it contains 30 to 95 mol % of a material having a critical temperature less than the temperature of the gas; (iii) when the final normal boiling point of the carbon black raw material is greater than 350 to 400 K and the temperature of the gas mixture is between 340 and 360 K, it contains 50 to 80 mol % of a material having a critical temperature less than the temperature of the gas; (iv) when the final normal boiling point of the carbon black raw material is greater than 400 to 450 K and the temperature of the gas mixture is between 390 and 420 K, it contains 50 to 75 mol % of a material having a critical temperature less than the temperature of the gas; (v) when the final normal boiling point of the carbon black raw material is greater than 450 to 500 K and the temperature of the gas mixture is between 440 and 460 K, it contains 40 to 65 mol % of a material having a critical temperature less than the temperature of the gas; (vi) when the final normal boiling point of the carbon black raw material is greater than 500 to 550 K and the temperature of the gas mixture is between 490 and 520 K, it contains 20 to 65 mol % of a material having a critical temperature less than the temperature of the gas; (vii) When the normal final boiling point of the carbon black raw material is greater than 550 to 610 K and the temperature of the gas mixture is between 540 and 570 K, it contains between 20 and 55 mol % of a material having a critical temperature less than the temperature of the gas; or (viii) when the final normal boiling point of the carbon black raw material is greater than 610 to 670 K and the temperature of the gas mixture is between 590 and 630 K, it contains 30 to 65 mol % of a material having a critical temperature less than the temperature of the gas; Here, the material preferably includes a plasma gas such as hydrogen, or a carbon black raw material.

[0092] When the carbon black feedstock contains two or more hydrocarbons, the final normal boiling point of the feedstock mixture is measured, and x in formula (V) and formula (VI) is calculated. dilutant It is possible to use the final normal boiling point in the calculation of . This is particularly useful when the carbon black feedstock contains hydrocarbons within a narrow normal boiling point distribution, such as ±30K.

[0093] The boiling point of a hydrocarbon feedstock can be measured by distillation or vacuum distillation. When more than one hydrocarbon feedstock (carbon black feedstock composition) is used, a boiling curve can be measured to obtain the "final boiling point" (or "last boiling point") as measured according to ASTM D86-04b. In general, the final boiling point can be considered as the boiling point of the hydrocarbon with the highest boiling point in the composition or fraction. The normal boiling point or the final normal boiling point is the respective boiling point at 1 atm.

[0094] However, formulas (V) and (VI) are preferably used for carbon black feedstocks that contain one hydrocarbon. Moreover, said hydrocarbon generally has a critical temperature above the temperature of the gas. This means that carbon black feedstocks that do not contain a certain proportion of plasma gas or materials that have a critical temperature below the temperature of the gas will form droplets in the reaction chamber or near the plasma zone. This also applies to the formulas described below.

[0095] For carbon black feedstock compositions, when there are more than one carbon black feedstock (or carbon black feedstock containing more than one compound), e.g., multiple hydrocarbons, the following formulas (IX) and (XVII) should be used. Both formulas can also be used for carbon black feedstocks containing only one hydrocarbon feedstock, i.e., only one carbon black feedstock (or carbon black feedstock containing one compound). The above compounds of the carbon black feedstock refer to compounds or materials that have a critical temperature above the temperature of the gas. In other words, there are more than one material that has a critical temperature above the temperature of the gas.

[0096] If the carbon black feedstock mixture contains compounds or materials with a critical temperature above the temperature of the gas as well as compounds or materials with a critical temperature below the temperature of the gas, only the materials or compounds with a critical temperature above the temperature of the gas are considered for the calculation. The materials or compounds with a critical temperature below the temperature of the gas will not condense and can act as a diluent for the materials with a critical temperature above the temperature of the gas. The temperature of the gas (gas mixture, plasma gas mixture) should be the lowest temperature present upstream of the plasma zone or the zone where the plasma is generated.

[0097] For example, the carbon black feedstock can be divided into two portions. The first portion contains all species with a critical temperature less than or equal to the temperature of the mixture, and the second portion contains all species with a critical temperature greater than the temperature of the mixture. The first portion is also called diluent, while the second portion is not a diluent. The number of species in the second portion is designated N. The maximum pressure of the carbon black feedstock without diluent is defined as follows:

[0098]

number

[0099] In this formula, x i vapour represents the mole fraction of species i in %, and P i s represents the vapor pressure of species i at the temperature of the mixture. To obtain a gas mixture, the mole fraction of diluent (e.g., in the mixture of the first and second parts) must be at least

[0100]

number

[0101] Combining equations (VII) and (VIII) gives the following equation (IX): Equations (VIII) and (IX) have the requirement that the minimum value is 0 (zero), since a negative value for the molar ratio simply means that no dilution is required, i.e., the molar ratio is zero.

[0102]

number

[0103] In the formula, x dilutant is the dilution degree, P [Pa] is the pressure of the plasma gas mixture, i represents each compound in the carbon black feedstock, and Σ i=1 N is the sum of i=1 to N, i is the compound index of the compound in the carbon black raw material, and x i vapour is the mole percentage of each compound in the carbon black feedstock, and P i s [Pa] is the vapor pressure of each compound i in the carbon black raw material at the plasma gas temperature T [K], and P i s is calculated according to formula (X).

[0104]

number

[0105] P0 [Pa] is atmospheric pressure, set to 101325 Pa, Δ vap H m,i [J / mol] is the standard molar enthalpy of vaporization of each compound in the carbon black feedstock (e.g., calculated according to formula (I)), R [J / mol / K] is the universal gas constant, i.e., 8.314463 J / mol / K, T [K] is the system temperature or temperature of the plasma gas mixture, and T b,i[K] is the standard (atmospheric pressure P0=101325 Pa) boiling point of each compound in the carbon black feedstock. The carbon black feedstock refers to the carbon black feedstock (i.e., the compounds in the carbon black feedstock) that have a critical temperature higher than the temperature of the gas.

[0106] Below are three example mixtures and the resulting dilution x dilutant Calculate.

[0107] Mixture 1 contains 10 mol% octane (C8H18, Tc=568K), 30 mol% nonane (C9H20, Tc=594K), 30 mol% dodecane (C12H26, Tc=658K), and 30 mol% docosane (C22, Tc=786K). Again, the critical temperature Tc of a material or substance is disclosed in Landolt Bernstein, Numbers and Functions, 6th Edition, Vol. 2 / 1, Table 21116, p. 328, Berlin-Heidelberg-New York: Springer-Verlag, 1971.

[0108] Mixture 2 contains 5 mol% C9H20, 10 mol% C10H22, 30 mol% C12H26, 20 mol% C14H30, 5 mol% C15H32, 5 mol% C16H34, 5 mol% C19H40, and 20 mol% C22H46.

[0109] Mixture 3 contained 15 mol% C10H22, 15 mol% C12H26, 10 mol% C14H30, 5 mol% C17H36, 5 mol% C18H28, 5 mol% C19H40, 20 mol% C22H46, and 25 mol% C23H48.

[0110] Table 3 shows the mole percentages of plasma gases and / or materials with critical temperatures below the temperature of the gases required to avoid condensation for mixtures 1 to 3. The system pressure or pressure P [Pa] of the gas / plasma gas mixture is 101325 Pa.

[0111] For example, mixture 3 at 550K contains only the carbon black feedstock or compounds (materials) in the carbon black feedstock that have a critical temperature above the temperature of the gas (i.e., 550K). The compound or material with the lowest critical temperature in the mixture is octane (C8H18, Tc=568K), where the temperature of the gas, i.e., 550K, is lower than the Tc of octane, 568K. Thus, all compounds in mixture 3 are dissolved at a dilution degree of x dilutant If one of the compounds or materials has a critical temperature that is less than the temperature of the gas, then that compound will not be used as a carbon black feedstock compound in the above formulas involving mole fractions.

[0112] Table 3: Molar percentages required to avoid condensation of plasma gases and / or materials with critical temperatures below that of the gas, calculated taking into account different gas temperatures.

[0113] [Table 3]

[0114] The plasma gas and carbon black feedstock should be mixed prior to subjecting the gases to the plasma zone, where the mole percent of the plasma gas, or the mole percent of the material having a critical temperature below the temperature of the gas (preferably the mole percent of the material having a critical temperature below the temperature of the gas), based on the total molar amount of the plasma gas including the carbon black feedstock, is greater than or equal to x. dilutant greater than, where x dilutant can be calculated according to formula (IX).

[0115]

number

[0116] In the formula, x dilutant is the dilution degree, P [Pa] is the pressure of the plasma gas mixture, i represents each compound in the carbon black feedstock (which has a critical temperature above the temperature of the gas mixture), and Σ i=1N is the sum of i=1 to N, i is the compound index of the compound in the carbon black raw material, and x i vapour is the mole percentage of each compound in the carbon black feedstock, and P i s [Pa] is the vapor pressure of each compound i in the carbon black raw material at the plasma gas temperature T [K], and P i s is calculated according to formula (X).

[0117]

number

[0118] P0 [Pa] is atmospheric pressure, set to 101325 Pa, Δ vap H m,i [J / mol] is the standard molar enthalpy of vaporization of each compound in the carbon black feedstock (e.g., calculated according to formula (I)), R [J / mol / K] is the universal gas constant, i.e., 8.314463 J / mol / K, T [K] is the system temperature or temperature of the plasma gas mixture, and T b,i [K] is the standard (atmospheric pressure P0=101325 Pa) boiling point of each compound in the carbon black feedstock. The carbon black feedstock refers to the carbon black feedstock (i.e., the compounds in the carbon black feedstock) that have a critical temperature above the temperature of the gas. Preferably, the mole percentage of the plasma gas is x dilutant Super and (x dilutant +20 mol%), and more preferably the mole percentage of the plasma gas is between (x dilutant +1mol%) and (x dilutant +15 mol%), and even more preferably the mole percentage of the plasma gas is between (x dilutant +3mol%) and (x dilutant +12 mol%), and most preferably the mole percentage of the plasma gas is between (x dilutant +5mol%) and (x dilutant+10mol%). The mole percentage of the plasma gas is at least x dilutant (or x dilutant and more preferably the mole percent of the plasma gas is at least (x dilutant +1 mol%), and even more preferably the mole percentage of the plasma gas is at least (x dilutant +3 mol%), and most preferably the mole percentage of the plasma gas is at least (x dilutant +5mol%).

[0119] dilution x dilutant refers to the mole percent of the plasma gas, the mole percent of the plasma gas that has a critical temperature below the temperature of the gas, and / or the mole percent of the material that has a critical temperature below the temperature of the gas. dilutant refers to the mole percentage of the plasma gas having a critical temperature below the temperature of the gas and / or the mole percentage of the material having a critical temperature below the temperature of the gas. More preferably, the dilution degree x dilutant refers to the mole percent of the plasma gas that has a critical temperature below the temperature of the gas, and the mole percent of the material that has a critical temperature below the temperature of the gas. Most preferably, the dilution degree x dilutant refers to the mole percent of the material that has a critical temperature below the temperature of the gas.

[0120] As previously mentioned, formula (XVII) represents the dilution degree x of the carbon black raw material or carbon black raw material mixture. dilutant The carbon feedstock and / or carbon feedstock mixture should contain one or more critical temperatures above the temperature of the gas.

[0121] Formula (XVII) is particularly useful for carbon black feedstocks that contain large amounts of different materials, for example carbon black feedstocks that contain unknown materials.

[0122] The entire carbon black feedstock is preferably considered for the calculation. Alternatively, only the carbon black feedstock material having a critical temperature above the temperature of the gas is considered for the calculation.

[0123] In equation (XVII), the carbon black feedstock is divided into 10 samples or fractions. For each fraction or sample, it is assumed that the fraction or sample consists of one pseudo-component (or material, or compound). In general, the component with the highest boiling point in each sample is considered the pseudo-component for the respective sample. The samples should have the same volume percent fraction, such as 1 / 10 volume percent, of the total carbon black feedstock. It is not necessary to divide the carbon black feedstock samples into exact equal volume fractions.

[0124] Preferably for unknown carbon black raw materials, atmospheric distillation experiments can be performed according to ASTM D86-04b. If the entire sample cannot be completely evaporated at atmospheric conditions (1 atm), vacuum distillation must be applied and recalculated to atmospheric conditions according to ASTM D5236-03. The entire mixture (e.g., 100 ml) is separated by distillation into 10 samples / fractions (e.g., 10 ml). The standard boiling point temperature of the last drop of each sample i is determined and expressed as T b,i It is represented by T b,i is the standard boiling point [K] for each pseudocomponent. For each sample, the mass and molecular weight are determined. The molecular weight can be determined by measuring the number average molecular weight using vapor pressure osmometry (ASTM D3592-77).

[0125] The boiling points of materials referred to in this specification refer to the standard boiling points, i.e. the boiling points at atmospheric pressure P=101325 Pa.

[0126] The number of moles per sample is obtained using equation (XI).

[0127]

number

[0128] In this formula, the number of moles of sample i is n i and the mass of sample i is m i and the molecular weight is M i and the amount of each sample is determined.

[0129] The mole fraction of each sample is determined by the following formula:

[0130]

number

[0131] For each sample, the standard entropy of evaporation, Δ vap S m = 88 J / (mol K) pseudo standard heat of vaporization Δ vap H m,i is calculated.

[0132]

number

[0133] For each sample i, the pseudo vapor pressure p pseudo,i s is calculated according to the following formula:

[0134]

number

[0135] P0 [Pa] is atmospheric pressure, set to 101325 Pa, Δ vap H m,i [J / mol] is the standard molar enthalpy of vaporization of each sample (or fraction) of carbon black raw material (e.g., calculated according to equation (I)), R [J / mol / K] is the universal gas constant, i.e., 8.314463 J / mol / K, T [K] is the system temperature or temperature of the plasma gas mixture, and T b,i[K] is the standard (atmospheric pressure P0 = 101325 Pa) boiling point of each sample (or fraction) of the carbon black raw material.

[0136] The pseudo pressure is calculated according to the following formula:

[0137]

number

[0138] The required mole fraction of plasma gas in a mixture of 10 pseudo-components (preferably with a critical temperature below the temperature of the mixture) is calculated by the following formula:

[0139]

number

[0140] Combining formulas (XV) and (XVI) gives the following formula (XVII): Formulas (XVI) and (XVII) have the condition that the minimum value is 0 (zero), since a negative value for the molar ratio simply means that no dilution is required, i.e., the molar ratio is zero.

[0141]

number

[0142] In the formula, x dilutant is the dilution factor, P [Pa] is the pressure of the plasma gas mixture, i represents each sample of carbon black feedstock (preferably one having a critical temperature above the temperature of the plasma gas mixture, more preferably the entire carbon black feedstock), and Σ i=1 10 is the sum of i=1 to N, where i is the compound index of the carbon black raw material sample, and x pseudo,i vapour is the mole percentage of each sample of carbon black raw material, and P pseudo,i s[Pa] is the vapor pressure of each sample i of the carbon black raw material at the plasma gas temperature T [K], and P pseudo,i s is calculated according to formula (XVIII).

[0143]

number

[0144] P0 [Pa] is atmospheric pressure, set to 101325 Pa, Δ vap H m,i [J / mol] is the standard molar enthalpy of vaporization of each sample of carbon black raw material (e.g., calculated according to formula (XIII)), R [J / mol / K] is the universal gas constant, i.e., 8.314463 J / mol / K, T [K] is the system temperature or temperature of the plasma gas mixture, and T b,i [K] is the standard (atmospheric pressure P0=101325 Pa) boiling point of each sample of carbon black feedstock. The carbon black feedstock refers to the entire carbon black feedstock (i.e., the compounds in the carbon black feedstock). Alternatively, the carbon black feedstock refers to the carbon black feedstock (i.e., the compounds in the carbon black feedstock) that have a critical temperature above the temperature of the gas.

[0145] Equation (XVII) is preferably used to calculate the desired dilution of an unknown carbon black feedstock mixture. However, it is possible to use equation (XVII) for the above calculations for a known carbon black feedstock. An unknown carbon black feedstock refers to a carbon black feedstock that contains a large amount of different compounds that are partially unidentified. Nevertheless, it is possible to analyze all compounds and fractions in the mixture of the carbon black feedstock mixture.

[0146] The plasma gas and the carbon black feedstock are mixed prior to subjecting the gas to the plasma zone, wherein the mole percent of the plasma gas, the mole percent of the plasma gas having a critical temperature below the temperature of the gas, and / or the mole percent of materials having a critical temperature below the temperature of the gas (preferably the mole percent of the plasma gas having a critical temperature below the temperature of the gas) is based on the total molar amount of the plasma gas including the carbon black feedstock, and wherein the mole percent of the plasma gas, the mole percent of the material having a critical temperature below the temperature of the gas (preferably the mole percent of the plasma gas having a critical temperature below the temperature of the gas) is based on the total molar amount of the plasma gas including the carbon black feedstock, and wherein the mole percent of the material having a critical temperature below the temperature of the gas is based on the total molar amount of the plasma gas including the carbon black feedstock, and dilutant greater than, where x dilutant is calculated according to formula (XVII).

[0147]

number

[0148] In the formula, x dilutant is the dilution factor, P [Pa] is the pressure of the plasma gas mixture, i represents each sample of carbon black feedstock (preferably one having a critical temperature above the temperature of the plasma gas mixture, more preferably the entire carbon black feedstock), and Σ i=1 10 is the sum of i=1 to N, where i is the compound index of the carbon black raw material sample, and x pseudo,i vapour is the mole percentage of each sample of carbon black raw material, and P pseudo,i s [Pa] is the vapor pressure of each sample i of the carbon black raw material at the plasma gas temperature T [K], and P pseudo,i s is calculated according to formula (XVIII).

[0149]

number

[0150] P0 [Pa] is atmospheric pressure, set to 101325 Pa, Δ vap H m,i[J / mol] is the standard molar enthalpy of vaporization of each sample of carbon black raw material (e.g., calculated according to formula (XIII)), R [J / mol / K] is the universal gas constant, i.e., 8.314463 J / mol / K, T [K] is the system temperature or temperature of the plasma gas mixture, and T b,i [K] is the standard (atmospheric pressure P0 = 101325 Pa) boiling point of each sample of carbon black raw material.

[0151] Preferably, the mole percentage of the plasma gas is x dilutant Super and (x dilutant +20 mol%), and more preferably the mole percentage of the plasma gas is between (x dilutant +1mol%) and (x dilutant +15 mol%), and even more preferably the mole percentage of the plasma gas is between (x dilutant +3mol%) and (x dilutant +12 mol%), and most preferably the mole percentage of the plasma gas is between (x dilutant +5mol%) and (x dilutant +10mol%). The mole percentage of the plasma gas is at least x dilutant (or x dilutant and more preferably the mole percent of the plasma gas is at least (x dilutant +1 mol%), and even more preferably the mole percentage of the plasma gas is at least (x dilutant +3 mol%), and most preferably the mole percentage of the plasma gas is at least (x dilutant +5 mol%). The carbon black feedstock refers to the entire carbon black feedstock (i.e., the compounds in the carbon black feedstock). Alternatively, the carbon black feedstock refers to the carbon black feedstock (i.e., the compounds in the carbon black feedstock) that has a critical temperature above the temperature of the gas.

[0152] The carbon black feedstock, which is mixed with the gas before subjecting it to the plasma zone, can be analyzed by distillation of the carbon black feedstock, where the carbon black feedstock is separated into 10 samples / fractions by distillation, and the temperature at which the last drop of each sample / fraction is distilled is the boiling point, T b,i [K]. It is desirable for the 10 samples / fractions to have the same mole percentages of the carbon black feedstock being analyzed. Preferably, each sample contains compounds with similar boiling points, where similar refers to boiling points of ±20K.

[0153] It may be advantageous to use more than 10 samples or fractions. For example, the compounds of carbon black feedstock have a wide range of boiling points. Thus, the formula can be modified so that the number of samples is 15, 20, 25, 30 or 40.

[0154] Table 4 shows the formula (XVII) for x dilutant 1 shows boiling curves, measured according to ASTM D86-04b, obtained from exemplary samples of carbon black feedstock for calculating the boiling point of the carbon black feedstock. The entire carbon black feedstock is used. The standard boiling point readings are the temperatures of the last drops of each fraction.

[0155] Table 4: Distillation of exemplary carbon black feedstocks according to ASTM D86-04b.

[0156] [Table 4]

[0157] During distillation, the sample is divided into 10 samples, each having approximately 1 / 10% by volume of the initial carbon black feedstock (carbon black feedstock mixture) (see Table 5). The molecular weight was determined by measuring the number average molecular weight using vapor pressure osmometry (ASTM D3592-77). The number of moles per sample was obtained using equation (XI). The mole fraction of each sample is calculated.

[0158] Table 5: Calculation of mole fractions obtained from the distillations described in Table 4.

[0159] [Table 5]

[0160] In Table 4, the pressure P0 is 1.01325 bar instead of 101325 Pa. Therefore, Σ i=1 10 [x pseudo,i vapour / (100P pseudo,i s )] is 1.10700611bar -1 and therefore, x at an operating pressure P of 1 bar and a temperature T of 573.15 K dilutant is as follows:

[0161]

number

[0162] Dilution or minimum dilution x for various system pressures and temperatures dilutant Calculate the following table.

[0163] Table 6: Minimum dilution for various system pressures and temperatures

[0164] [Table 6]

[0165] Therefore, at least one of formula (V), formula (IX) or formula (XVII) should be used to calculate the mole percentage of the plasma gas or the mole percentage of the material having a critical temperature below the temperature of the gas (preferably the mole percentage of the material having a critical temperature below the temperature of the gas) based on the total molar amount of the plasma gas containing the carbon black raw material, i.e., the plasma gas before being subjected to the plasma zone. Preferably, all of formula (V), formula (IX) and formula (XVII) are used.

[0166] In other words, the plasma gas and the carbon black feedstock are mixed prior to subjecting the gases to the plasma zone, and the mole percent of the plasma gas, the mole percent of the plasma gas having a critical temperature below the temperature of the gas, and / or the mole percent of the material having a critical temperature below the temperature of the gas (preferably the mole percent of the plasma gas having a critical temperature below the temperature of the gas) is based on the total molar amount of the plasma gas including the carbon black feedstock, and is greater than or equal to x. dilutant Greater than x dilutant is calculated according to formula (V), formula (IX) and / or formula (XVII).

[0167]

number

[0168] In the formula, x dilutant is the dilution factor, P [Pa] is the pressure of the plasma gas mixture, P0 [Pa] is the atmospheric pressure, which is set to 101325 Pa, and Δ vap H m where [J / mol] is the standard molar enthalpy of vaporization of the carbon black raw material (e.g., calculated according to formula (I)), R [J / mol / K] is the universal gas constant, i.e., 8.314463 J / mol / K, T [K] is the system temperature or temperature of the plasma gas mixture, and T b [K] is the standard boiling point (atmospheric pressure P0 = 101325 Pa) of the carbon black raw material.

[0169]

number

[0170] In the formula, x dilutant is the dilution degree, P [Pa] is the pressure of the plasma gas mixture, i represents each compound in the carbon black feedstock, and Σ i=1 N is the sum of i=1 to N, i is the compound index of the compound in the carbon black raw material, and xi vapour is the mole percentage of each compound in the carbon black feedstock, and P i s [Pa] is the vapor pressure of each compound i in the carbon black raw material at the plasma gas temperature T [K], and P i s is calculated according to formula (X).

[0171]

number

[0172] P0 [Pa] is atmospheric pressure, set to 101325 Pa, Δ vap H m,i [J / mol] is the standard molar enthalpy of vaporization of each compound in the carbon black feedstock (e.g., calculated according to formula (I)), R [J / mol / K] is the universal gas constant, i.e., 8.314463 J / mol / K, T [K] is the system temperature or temperature of the plasma gas mixture, and T b,i [K] is the standard boiling point (atmospheric pressure P0 = 101325 Pa) of each compound in the carbon black raw material.

[0173]

number

[0174] In the formula, x dilutant is the dilution factor, P [Pa] is the pressure of the plasma gas mixture, i represents each sample of carbon black raw material, and Σ i=1 10 is the sum of i=1 to N, where i is the compound index of the carbon black raw material sample, and x pseudo,i vapour is the mole percentage of each sample of carbon black raw material, and P pseudo,i s [Pa] is the vapor pressure of each sample i of the carbon black raw material at the plasma gas temperature T [K], and P pseudo,i sis calculated according to formula (XVIII).

[0175]

number

[0176] P0 [Pa] is atmospheric pressure, set to 101325 Pa, Δ vap H m,i [J / mol] is the standard molar enthalpy of vaporization of each sample of carbon black raw material (e.g., calculated according to equation (XIII)), R [J / mol / K] is the universal gas constant, i.e., 8.314463 J / mol / K, T [K] is the system temperature or temperature of the plasma gas mixture, and T b,i [K] is the standard (atmospheric pressure P0 = 101325 Pa) boiling point of each sample of carbon black raw material.

[0177] Preferably, the mole percentage of the plasma gas is x dilutant Super and (x dilutant +20 mol%), and more preferably the mole percentage of the plasma gas is between (x dilutant +1mol%) and (x dilutant +15 mol%), and even more preferably the mole percentage of the plasma gas is between (x dilutant +3mol%) and (x dilutant +12 mol%), and most preferably the mole percentage of the plasma gas is between (x dilutant +5mol%) and (x dilutant +10mol%). The mole percentage of the plasma gas is at least x dilutant (or x dilutant and more preferably the mole percent of the plasma gas is at least (x dilutant +1 mol%), and even more preferably the mole percentage of the plasma gas is at least (x dilutant +3 mol%), and most preferably the mole percentage of the plasma gas is at least (x dilutant+5 mol%). The carbon black feedstock should refer to the carbon black feedstock (i.e., the compounds in the carbon black feedstock) that have a critical temperature above the temperature of the gas. Alternatively, the carbon black feedstock should refer to the entire carbon black feedstock (i.e., the compounds in the carbon black feedstock).

[0178] Therefore, x dilutant can be calculated according to formula (V), formula (IX) and formula (XVII), can be calculated according to formula (V), formula (IX) or formula (XVII), can be calculated according to formula (V) and formula (XVII), can be calculated according to formula (V) and formula (IX), can be calculated according to formula (V) or formula (XVII), can be calculated according to formula (V) or formula (IX).

[0179] In general, it is desirable for the temperature of the plasma gas to be as low as possible to avoid cleavage of C—C bonds in the carbon black feedstock.

[0180] The present invention further relates to the use of a minimum molar percentage of a plasma gas, a plasma gas having a critical temperature below the temperature of the gas, and / or a material having a critical temperature below the temperature of the gas (preferably a plasma gas having a critical temperature below the temperature of the gas), preferably for a reactor according to the present invention, preferably utilizing a method according to the present invention, for preventing the formation of droplets in a reactor (or condensation in a reactor) in carbon black production, where the plasma gas and the carbon black feedstock are mixed before subjecting the gases to the plasma zone, and the minimum molar percentage is greater than or equal to x, based on the total molar amount of the plasma gas including the carbon black feedstock. dilutant Greater than x dilutant is calculated according to formula (V), formula (IX) and / or formula (XVII).

[0181]

number

[0182] In the formula, x dilutant is the dilution factor, P [Pa] is the pressure of the plasma gas mixture, P0 [Pa] is the atmospheric pressure, which is set to 101325 Pa, and Δ vap H m where [J / mol] is the standard molar enthalpy of vaporization of the carbon black raw material (e.g., calculated according to formula (I)), R [J / mol / K] is the universal gas constant, i.e., 8.314463 J / mol / K, T [K] is the system temperature or temperature of the plasma gas mixture, and T b [K] is the standard boiling point (atmospheric pressure P0 = 101325 Pa) of the carbon black raw material.

[0183]

number

[0184] In the formula, x dilutant is the dilution degree, P [Pa] is the pressure of the plasma gas mixture, i represents each compound in the carbon black feedstock, and Σ i=1 N is the sum of i=1 to N, i is the compound index of the compound in the carbon black raw material, and x i vapour is the mole percentage of each compound in the carbon black feedstock, and P i s [Pa] is the vapor pressure of each compound i in the carbon black raw material at the plasma gas temperature T [K], and P i s is calculated according to formula (X).

[0185]

number

[0186] P0 [Pa] is atmospheric pressure, set to 101325 Pa, Δ vap H m,i[J / mol] is the standard molar enthalpy of vaporization of each compound in the carbon black feedstock (e.g., calculated according to formula (I)), R [J / mol / K] is the universal gas constant, i.e., 8.314463 J / mol / K, T [K] is the system temperature or temperature of the plasma gas mixture, and T b,i [K] is the standard boiling point (atmospheric pressure P0 = 101325 Pa) of each compound in the carbon black raw material.

[0187]

number

[0188] In the formula, x dilutant is the dilution factor, P [Pa] is the pressure of the plasma gas mixture, i represents each sample of carbon black raw material, and Σ i=1 10 is the sum of i=1 to N, where i is the compound index of the carbon black raw material sample, and x pseudo,i vapour is the mole percentage of each sample of carbon black raw material, and P pseudo,i s [Pa] is the vapor pressure of each sample i of the carbon black raw material at the plasma gas temperature T [K], and P pseudo,i s is calculated according to formula (XVIII).

[0189]

number

[0190] P0 [Pa] is atmospheric pressure, set to 101325 Pa, Δ vap H m,i [J / mol] is the standard molar enthalpy of vaporization of each sample of carbon black raw material (e.g., calculated according to equation (XIII)), R [J / mol / K] is the universal gas constant, i.e., 8.314463 J / mol / K, T [K] is the system temperature or temperature of the plasma gas mixture, and T b,i[K] is the standard (atmospheric pressure P0 = 101325 Pa) boiling point of each sample of carbon black raw material.

[0191] Preferably, the mole percentage of the plasma gas is x dilutant Super and (x dilutant +20 mol%), and more preferably the mole percentage of the plasma gas is between (x dilutant +1mol%) and (x dilutant +15 mol%), and even more preferably the mole percentage of the plasma gas is between (x dilutant +3mol%) and (x dilutant +12 mol%), and most preferably the mole percentage of the plasma gas is between (x dilutant +5mol%) and (x dilutant +10mol%).

[0192] (x dilutant +20mol%) or (x dilutant Expressions in brackets such as +xx mol%) indicate an additional mole percentage, such as 20 mol%, plus x. dilutant Therefore, the above expressions in parentheses can be formulated without the parentheses.

[0193] It is also possible to provide a method for automatically and continuously adjusting the mole percentage of the plasma gas for carbon black production, the plasma gas having a critical temperature below the temperature of the gas, and / or the material having a critical temperature below the temperature of the gas to the minimum mole percentage required to prevent the formation of droplets in the reactor.

[0194] Furthermore, the present invention relates to the use of at least two injection means for carbon black raw material, preferably according to the present invention, to prevent the formation of droplets in the reactor (or condensation in the reactor) in a reactor for producing carbon black having a flow path along a central longitudinal axis of the reactor, preferably in a reactor according to the present invention, comprising (A) a reaction chamber, (B) injection means for feeding the carbon black raw material, and (C) means for generating a plasma in the reaction chamber, thereby forming a plasma zone, wherein (i) the injection means for feeding the carbon black raw material are located upstream of the plasma zone, (ii) the injection means for feeding the carbon black raw material are located in the plasma zone, but preferably after the region where the plasma is generated, and / or (iii) the injection means for feeding the carbon black raw material are located downstream of the plasma zone, preferably immediately after the plasma zone.

[0195] The at least two injection means should be: (i) an injection means for supplying carbon black feedstock located upstream of the plasma zone, and (ii) an injection means for supplying carbon black feedstock located in the plasma zone, but preferably after the region where the plasma is generated.

[0196] The pressure in the plasma zone and / or the pressure of the plasma gas in the plasma zone is 0.1 to 1.3 bar, for example 0.1 to 1.2 bar, 0.1 to 1.1 bar, 0.1 to 1 bar, 0.2 to 1 bar, 0.2 to less than 1 bar, 0.1 to 0.5 bar, 0.2 to 0.9 bar, 0.3 to 0.8 bar, or 0.3 to 0.5 bar, preferably the pressure upstream of the plasma zone and / or the pressure of the plasma gas upstream of the plasma zone is higher than the pressure in the plasma zone and / or the pressure of the plasma gas in the plasma zone. At a pressure below 0.3 bar, acetylene is more likely to be obtained as an intermediate in carbon black production. Since acetylene affects the produced carbon black, it is desirable that the pressure in the plasma zone and / or the pressure of the plasma gas in the plasma zone is less than 0.3 bar or more than 0.3 bar. In plasma-assisted production, the reaction time for carbon black formation is very short. Reducing the pressure is beneficial for the uniform properties of the produced carbon black.

[0197] The pressure upstream of the plasma zone and / or the pressure of the plasma gas upstream of the plasma zone can be 0.1-3 bar, for example 0.2-2.6 bar, 0.5-2.5 bar, 0.9-2.2 bar, 1-2 bar, 1.5-2 bar, 1.6-3 bar, 1-1.5 bar, or 1.1-1.4 bar, preferably the pressure upstream of the plasma zone and / or the pressure of the plasma gas upstream of the plasma zone is higher than the pressure in the plasma zone and / or the pressure of the plasma gas in the plasma zone.

[0198] The pressure in the reaction chamber can simply be reduced using a pump or a Laval nozzle can be used. The reaction chamber can be designed as a Laval nozzle such that the gas flows at a velocity less than 1 Ma before the constriction of the Laval nozzle, at a velocity of 1 Ma at the constriction of the Laval nozzle, and at a velocity greater than 1 Ma after the constriction of the Laval nozzle, and the plasma is generated at the constriction of the Laval nozzle. The reaction chamber can be designed as a Laval nozzle, and the plasma is generated at the constriction of the Laval nozzle.

[0199] The reaction chamber can be designed as a Laval nozzle such that the gas flow has a velocity of less than 1 Ma before the constriction of the Laval nozzle, has a velocity of less than 1 Ma at the constriction of the Laval nozzle, and has a velocity of less than 1 Ma after the constriction of the Laval nozzle, and a plasma is generated at the constriction of the Laval nozzle, the gas flow velocity at the constriction being greater than before the constriction and the gas flow velocity after the constriction being greater than at the constriction.

[0200] To ensure homogeneous mixing of the plasma gas with the raw material, it is desirable to provide swirl to the plasma gas. In addition, swirl can be used simultaneously to stabilize the plasma. Thus, before subjecting the gas to the plasma zone, the plasma gas can be swirled, preferably the plasma gas has a swirl number of 0.2-1.2, preferably 0.3-0.8, more preferably 0.5-0.7, even more preferably 0.55-0.65. Generally, the swirl strength is a measure of the angular momentum of the gas. It is characterized by the swirl number S, which is defined as the ratio of the axial flux of the angular momentum to the axial flux of the axial momentum (Gupta et al., 1984).

[0201] The swirl can be introduced using a swirl element. The swirl element can comprise vanes for generating the swirl, or the plasma gas and / or the carbon black feedstock is injected tangentially, for example into one or more tangential inlets. For tangential injection of the plasma gas and / or the carbon black feedstock, the injection is preferably carried out in a tubular conduit, in particular a tubular conduit connected to the reaction chamber. It is particularly preferred that the swirl is introduced upstream of the plasma zone.

[0202] The plasma can be generated in response to excitation of a plasma gas by microwave energy, thereby generating a plasma zone, where the microwave radiation is applied perpendicular to a central longitudinal axis of the reactor or to the direction of plasma gas flow, and / or the microwave radiation is applied radially and circumferentially relative to the central longitudinal axis of the reactor or to the direction of plasma gas flow. Preferably, perpendicular microwave radiation is applied from one direction.

[0203] It is also possible to inject HO and / or silica into the product mixture after (downstream) the plasma zone. Preferably, HO is injected upstream of the plasma zone. HO and / or silica can tailor the surface properties of the produced carbon black.

[0204] The temperature in the plasma zone can be between 1200-5000 K, for example 1300-4000 K, 1300-3000 K, 1400-3500 K, 1300-2500 K, 1300-2000 K, 1300-1800 K, or 1500-3000 K. Temperature generally refers to the temperature of the plasma.

[0205] The carbon black feedstock may be any suitable feedstock for carbon black production. For example, the carbon black feedstock is preferably liquid at 23° C. and 1 atm. The carbon black feedstock may include non-aromatic feedstocks, aromatic feedstocks, aliphatic feedstocks, aliphatic oils, sustainable feedstocks, renewable carbon black feedstocks and / or bio-based feedstocks. The above feedstocks are referred to as the first and / or second carbon black feedstocks.

[0206] Sustainable carbon black feedstocks (i.e., feedstocks for carbon black), such as aliphatic oils, renewable carbon black feedstocks and biomass-based feedstocks, have a high content of aliphatic C-C bonds and a low content of aromatic C-C bonds. The aliphatic C-C bonds are weak compared to C-H or aromatic C-C bonds. Therefore, primarily the C-C bonds of sustainable carbon black feedstocks are broken, but the cleavage of C-H bonds is favored to obtain unsaturated species for the formation of carbon black.

[0207] The carbon black feedstock (i.e., the feedstock for carbon black) may be or include a non-aromatic feedstock, an aromatic feedstock, an aliphatic feedstock, an aliphatic oil, a sustainable feedstock, a renewable carbon black feedstock, and / or a bio-based feedstock. Thus, the carbon black feedstock is not limited to renewable carbon black feedstocks, sustainable feedstocks, and / or bio-based feedstocks.

[0208] Preferably, the aliphatic feedstock comprises a high content of aliphatic material (feedstock for carbon black derived from an aliphatic feedstock), such as 20-100% by weight, e.g. 40-100% by weight, 50-99% by weight, 60-95% by weight, or 80-90% by weight, based on the total weight of the feedstock for carbon black. Sustainable feedstocks, renewable carbon black feedstocks and / or bio-based feedstocks often comprise such high contents of aliphatic feedstock.

[0209] Sustainable carbon black feedstocks generally refer to feedstocks with a high content of aliphatic C-C bonds, preferably a low content of aromatic C-C bonds. Sustainable carbon black feedstocks can include aliphatic oils, renewable carbon black feedstocks, and biomass-based feedstocks. Biomass-based feedstocks, sustainable carbon black feedstocks and / or renewable carbon black feedstocks can be distinguished from fossil-based feedstocks by measuring the C14 content in the feedstock (radiocarbon dating). The relative amount of C14 atoms compared to C12 (C14 to C12 ratio) is lower in fossil-based feedstocks compared to biomass-based feedstocks.

[0210] Preferably, the carbon black raw material is a renewable carbon black raw material. The renewable carbon black raw material may comprise a plant-based raw material, preferably a non-edible plant-based raw material and / or a waste plant-based raw material. As used herein, the term "non-edible" refers to material that is not suitable for human consumption. The term "waste" refers to material that is discarded or disposed of, e.g. after use, as unsuitable or no longer useful for its intended purpose. With regard to edible oils, i.e. cooking oils, used cooking oils are considered waste.

[0211] The renewable carbon black feedstock may comprise a solid component and / or a liquid component. Preferably, the renewable carbon black feedstock may comprise a liquid component.

[0212] The renewable carbon black feedstock may preferably comprise vegetable-based oil, more preferably non-edible vegetable-based oil and / or waste vegetable-based oil.

[0213] Renewable carbon black feedstocks according to the present invention may include waste wood including wood, grass, cellulose, hemicellulose, lignin, natural rubber and / or synthetic rubber obtained from renewable sources, black liquor, tall oil, rubber seed oil, tobacco seed oil, castor oil, pongamia oil, crambe oil, neem oil, apricot kernel oil, rice bran oil, cashew nut shell oil, Cyperus esculentus oil, cooking oil, distillation residue from a biodiesel plant, or any mixture or combination thereof.

[0214] As used herein, the term "wood" refers to the porous and fibrous structural tissue found in the stems and roots of trees and other woody plants. Suitable examples of wood include, but are not limited to, pine, spruce, larch, juniper, ash, hornbeam, birch, alder, beech, oak, pin, horse chestnut, mulberry, or mixtures thereof. Suitable examples of grass include, but are not limited to, cereal grasses such as corn, wheat, rice, barley or millet; bamboo and grasses in natural grasslands, and species cultivated in lawns and pastures. Suitable examples of lignin include, but are not limited to, lignin and lignosulfonates removed by the Kraft process. The waste material containing natural rubber and / or synthetic rubber obtained from renewable raw materials may be tires, cable sheaths, tubes, conveyor belts, shoe soles, hoses, or mixtures thereof. Natural rubber can be derived from the rubber tree (Helvea brasiliensis), guayule, and dandelion. Synthetic rubbers include styrene-butadiene rubbers such as emulsion styrene-butadiene rubber (ESBR), solution styrene-butadiene rubber (SSBR), polybutadiene, polyisoprene, ethylene-propylene-diene rubber (EPDM), ethylene-propylene rubber (EPM), butyl rubber, halogenated butyl rubber, chlorinated polyethylene, chlorosulfonated polyethylene, acrylonitrile-butadiene rubber, hydrogenated acrylonitrile-butadiene rubber, polychloroprene, acrylate rubber, ethylene-vinyl acetate rubber, ethylene-acrylic rubber, epichlorohydrin rubber, silicone rubber, fluorosilicone rubber, fluorocarbon rubber, or mixtures or combinations thereof. Synthetic rubbers such as polybutadiene can be produced from alcohol obtained by fermentation of plant biomass. A suitable preparation of alcohol obtained by fermentation and the preparation of polybutadiene from such alcohol is described in EP 2 868 697 A1.

[0215] As used herein, the term "cooking oil" refers to edible oils used for food preparation, such as frying, baking, and other types of cooking. According to the present invention, the cooking oil may include rice bran oil, rapeseed oil, linseed oil, palm oil, coconut oil, canola oil, soybean oil, sunflower oil, cottonseed oil, pine seed oil, olive oil, corn oil, grapeseed oil, safflower oil, acai palm oil, jambu oil, sesame oil, chia seed oil, hemp oil, perilla oil, peanut oil, stillingia oil, cashew nut oil, Brazil nut oil, macadamia nut oil, walnut oil, almond oil, hazelnut oil, beech nut oil, candlenut oil, chestnut oil, or any mixture or combination thereof. The cooking oil of the present invention may be used cooking oil. As used herein, the term "used cooking oil" refers to oil from a commercial or industrial food processing operation, such as a restaurant, that has been used for food preparation, such as cooking or frying.

[0216] The solid component may be selected from waste materials including, but not limited to, wood, grass, cellulose, hemicellulose, lignin, natural rubber and / or synthetic rubber obtained from renewable sources, or any mixture or combination thereof.

[0217] The liquid component may be selected from, but is not limited to, black liquor, tall oil, rubber seed oil, tobacco seed oil, castor oil, pongamia oil, crambe oil, neem oil, apricot kernel oil, rice bran oil, cashew nut shell oil, cyperus esculentus oil, cooking oil, distillation residue from biodiesel plants, or any mixture or combination of the above. Some oils may be solid at room temperature, e.g., at a temperature of 25°C, but may be liquid at elevated temperatures, e.g., at temperatures above 25°C, e.g., in the range of 25-100°C. As used herein, the term "black liquor" refers to a by-product from the Kraft process derived from the sulfate and soda process of producing cellulose pulp.

[0218] Non-edible plant-based feedstocks may include, but are not limited to, waste materials including wood, cellulose, hemicellulose, lignin, black liquor, tall oil, rubber seed oil, tobacco seed oil, castor oil, pongamia oil, crambe oil, neem oil, apricot kernel oil, rice bran oil, cashew nut shell oil, Cyperus esculentus oil, distillation residues from biodiesel plants, natural rubber and / or synthetic rubber obtained from renewable feedstocks, or any mixture or combination thereof.

[0219] Waste plant-based feedstocks may include, but are not limited to, waste materials including natural rubber and / or synthetic rubber derived from renewable sources, used cooking oil, or any mixture or combination thereof.

[0220] The carbon black raw material may include tall oil. The terms "tall oil" and "unrefined tall oil" may be used interchangeably throughout the specification unless otherwise specified. Tall oil is derived from chemical pulping of wood. Typically, tall oil is a mixture containing resin acids, fatty acids, sterols, alcohols and further alkyl hydrocarbon derivatives. Tall oil may be a natural unrefined product or a refined product. Refined tall oil may include tall oil fatty acids, tall oil fatty rosin, distilled tall oil and tall oil pitch. Tall oil may be distilled to obtain tall oil resin acids containing a resin acid content of more than 10% by weight. Tall oil may also be refined into tall oil fatty acids, where the resin acid content is typically less than 10% by weight. Suitable examples of tall oil include, but are not limited to, SYLFAT® products, SYLVATAL® products, SYLVABLEND® products and SYLVAROS® products (all available from Kraton Corporation, USA), as well as tall oil products such as unrefined tall oil and Tall Oil 1 (available from UCY Energy, Germany).

[0221] Carbon black feedstocks (i.e., raw materials for carbon black) may in particular comprise tall oil pitch. Tall oil pitch is obtained as a non-volatile residue from the refining of tall oil by distillation and may be mixed with the fore-runs of tall oil refining. The yield of tall oil pitch in the refining process may range from about 15 to 50% by weight, depending for example on the quality and composition of the tall oil. Tall oil pitch typically comprises neutrals, free acids including resin acids and fatty acids, fatty acid esters, bound and free sterols, and polymeric compounds. Furthermore, metals, metal cations, and inorganic-organic compounds including metal resinates and fatty acid salts can be found in tall oil pitch. Metal cations typically originate from wood and fertilizers. Suitable examples of tall oil pitches include, but are not limited to, SYLVABLEND® products, such as SYLVABLEND FA7002, SYLVABLEND PF40, SYLVABLEND PF60 and SYLVABLEND SF75 (all available from Kraton Corporation, USA), and Tall Oil 1, UCY-TOF40 and UCY-TOF60 (all available from UCY Energy, Germany).

[0222] According to the present invention, the carbon black feedstock (i.e., the feedstock for carbon black) can be a mixture of renewable carbon black feedstock and conventional carbon black feedstock. The conventional carbon black feedstock can be aliphatic or aromatic, saturated or unsaturated hydrocarbons or mixtures thereof, coal tar distillates, residual oils produced during catalytic cracking of petroleum fractions, residual oils produced during olefin production via cracking of naphtha or gas oil, natural gas, or mixtures or combinations thereof. Thus, the carbon black feedstock is not limited to a specific feedstock material. The carbon black feedstock can be liquid, solid and gaseous. The carbon black feedstock is preferably liquid or gaseous. Liquid here means that the feedstock is in liquid form at normal temperature and pressure (T=296.15K and P=101325Pa). For example, the gaseous carbon black feedstock can be an aliphatic feedstock such as methane, ethane, acetylene, ethylene, ethane, propyne, propane propene, butadiene, butane, pentane, or mixtures thereof.

[0223] The carbon black raw material of the present invention (i.e., raw material for carbon black) can contain renewable carbon black raw material in an amount of 10% by weight or more, based on the total weight of the carbon black raw material. For example, the carbon black raw material according to the present invention can contain renewable carbon black raw material in an amount of 15% by weight or more, 20% by weight or more, 25% by weight or more, 30% by weight or more, 35% by weight or more, 40% by weight or more, 45% by weight or more, 50% by weight or more, 55% by weight or more, 60% by weight or more, 65% by weight or more, 70% by weight or more, 75% by weight or more, 80% by weight or more, 85% by weight or more, 90% by weight or more, or 95% by weight or more, based on the total weight of the carbon black raw material. The carbon black raw material can contain renewable carbon black raw material in an amount of 10% by weight or more, preferably 15% by weight or more, particularly preferably 25% by weight or more, more preferably 50% by weight or more, even more preferably 85% by weight or more, and most preferably 99% by weight or more, based on the total weight of the carbon black raw material. The carbon black raw material can consist of renewable carbon black raw material.

[0224] The carbon black feedstock (i.e., feedstock for carbon black) of the present invention may comprise tall oil pitch in an amount of 5% by weight or more, for example 10% by weight or more, 15% by weight or more, 20% by weight or more, 25% by weight or more, 25% by weight or more, 30% by weight or more, 35% by weight or more, 40% by weight or more, 45% by weight or more, 50% by weight or more, 55% by weight or more, 60% by weight or more, 65% by weight or more, 70% by weight or more, 75% by weight or more, 80% by weight or more, 85% by weight or more, 90% by weight or more, or 95% by weight or more, based on the total weight of the carbon black feedstock. The carbon black feedstock may comprise tall oil pitch in an amount of 10% by weight or more, preferably 15% by weight or more, particularly preferably 25% by weight or more, more preferably 50% by weight or more, even more preferably 85% by weight or more, and most preferably 95% by weight or more, based on the total weight of the carbon black feedstock. The carbon black feedstock may consist of tall oil pitch.

[0225] The renewable carbon black feedstock of the present invention may comprise tall oil pitch in an amount of 5% by weight or more, for example 10% by weight or more, 15% by weight or more, 20% by weight or more, 25% by weight or more, 30% by weight or more, 35% by weight or more, 40% by weight or more, 45% by weight or more, 50% by weight or more, 55% by weight or more, 60% by weight or more, 65% by weight or more, 70% by weight or more, 75% by weight or more, 80% by weight or more, 85% by weight or more, 90% by weight or more, or 95% by weight or more, based on the total weight of the renewable carbon black feedstock. The renewable carbon black feedstock may comprise tall oil pitch in an amount of 10% by weight or more, preferably 15% by weight or more, particularly preferably 25% by weight or more, more preferably 50% by weight or more, even more preferably 85% by weight or more, and most preferably 95% by weight or more, based on the total weight of the renewable carbon black feedstock. The renewable carbon black feedstock may consist of tall oil pitch.

[0226] The carbon black of the present invention can have a pMC (modern carbon content) of 1% or more, e.g., 2% or more, 5% or more, 7% or more, 10% or more, 12% or more, 15% or more, 17% or more, 20% or more, 22% or more, 25% or more, 27% or more, 30% or more, 32% or more, 35% or more, 37% or more, 40% or more, 42% or more, 45% or more, 47% or more, 50% or more, 52% or more, 55% or more, 57% or more, 60% or more, 62% or more, 65% or more, 67% or more, 70% or more, 72% or more, 75% or more, 77% or more, 80% or more, 82% or more, 85% or more, 87% or more, 90% or more, 92% or more, 95% or more, 97% or more, or 99% or more, as measured according to ASTM D6866-20, Method B (AMS). 14 C / 12 The ratio of C is calculated and compared with the measurement made with oxalic acid II standard (NIST-4990C). The measured value (pMC) is corrected by d13C measured using an isotope ratio mass spectrometer (IRMS). The carbon black of the present invention can have a pMC (modern carbon content) of preferably 10% or more, particularly preferably 15% or more, more preferably 50% or more, even more preferably 85% or more, and most preferably 90% or more, as measured according to ASTM D6866-20, Method B (AMS). The carbon black of the present invention can have a pMC (modern carbon content) of 100% as measured according to ASTM D6866-20, Method B (AMS).

[0227] Generally, 60-100% by weight of the carbon black raw material is made up of compounds containing at least 5 carbon atoms, preferably 90-100% by weight, more preferably 97-100% by weight, even more preferably 99-100% by weight, and most preferably 99.9-100% by weight. It is also possible for the entire carbon black raw material to be made up of compounds containing at least 5 carbon atoms.

[0228] The carbon black feedstock may be derived from biomethane. Preferably, the carbon black feedstock comprises 45-75% by volume methane, 25-55% by volume CO2, 0-10% by volume H2O, 0.01-5% by volume N2, 0.01-2% by volume O2, and 0-1% by volume H2.

[0229] As mentioned above, the plasma gas can comprise or be hydrogen and / or water, or the plasma gas can comprise or be a carbon black feedstock. Preferably, the plasma gas comprises or is hydrogen and is derived from the pyrolysis of a carbon black feedstock.

[0230] Hydrogen as plasma gas increases the concentration of H radicals and / or H+ ions, and therefore increases the yield of carbon black. Aliphatic C-C bonds are weaker compared to C-H or aromatic C-C bonds. Therefore, it is preferred to cleave C-H bonds while mainly breaking C-C bonds to obtain unsaturated species for the formation of carbon black. When using hydrogen as plasma gas, the high concentration of H radicals and / or H+ ions can accelerate the C-H scission by bimolecular or trimolecular reactions. This can result in higher yields and uniform properties of carbon black. This is particularly useful for sustainable carbon black materials.

[0231] The method may further include separating the carbon black and H2 present in the product mixture and / or providing the separated H2 as a plasma feed gas. Reusing the produced H2 makes the method environmentally friendly. CO, CO2, and H2O may also be separated from the product mixture.

[0232] The plasma feed gas or hot plasma feed gas should not be heated by burning fuel, which can reduce CO2 emissions. Preheating is preferably done only by using electricity and / or waste heat from carbon black production or other processes.

[0233] The carbon black produced is (a) 40~140m 2 / g, preferably 60 to 130m 2 / g, more preferably 65 to 120m 2 and an oil absorption number (OAN) measured according to ASTM D2414-18 in the range of 40 to 200 mL / 100 g, preferably 60 to 180 mL / 100 g, more preferably 80 to 160 mL / 100 g; (b) 40~120m 2 / g, preferably 50 to 100m 2 / g, more preferably 65 to 90m 2 and an oil absorption number (OAN) measured according to ASTM D2414-18 in the range of 40 to 180 mL / 100 g, preferably 50 to 160 mL / 100 g, more preferably 70 to 150 mL / 100 g, (c) 200~600m 2 / g, preferably 250 to 500m 2 / g, more preferably 300 to 450m 2 and / or an STSA surface area, measured according to ASTM D6556-17, in the range of 50-150 mL / 100 g, preferably 60-120 mL / 100 g, more preferably 70-100 mL / 100 g, and / or an oil absorption number (OAN), measured according to ASTM D2414-18, in the range of 50-150 mL / 100 g, preferably 60-120 mL / 100 g, more preferably 70-100 mL / 100 g. (d) 140~210m 2 / g, preferably 150 to 200m 2 / g, more preferably 160 to 190m 2The composition may have an STSA surface area, as measured according to ASTM D6556-17, in the range of 100 to 200 mL / 100 g, preferably 110 to 170 mL / 100 g, and more preferably 120 to 160 mL / 100 g, and an oil absorption (OAN), as measured according to ASTM D2414-18, in the range of 100 to 200 mL / 100 g, preferably 110 to 170 mL / 100 g, and more preferably 120 to 160 mL / 100 g.

[0234] The plasma gas flow rate (preferably hydrogen gas flow rate) is 10 Nm 3 / h~10000Nm 3 / h, e.g. 20Nm 3 / h~5000Nm 3 / h, 30Nm 3 / h~2000Nm 3 / h, 40Nm 3 / h~1000Nm 3 / h, or 50 Nm 3 / h~500Nm 3 / h. Preferably the gas flow rate is 40 Nm 3 / h~1000Nm 3 / h, and most preferably the gas flow rate is 50 Nm 3 / h~500Nm 3 / h. The desired flow influences the plasma zone, which means the area where the plasma is present. The plasma zone can be enlarged by reducing the gas flow, preferably when microwave plasma is used. Similarly, the plasma can be adjusted by the power of the plasma generator.

[0235] Additionally, a reactor for producing carbon black having a flow path along a central longitudinal axis of the reactor comprises: (A) a reaction chamber; (B) an injection means for supplying carbon black feedstock; and (C) means for generating a plasma within the reaction chamber, thereby forming a plasma zone; wherein (i) the injection means for supplying the carbon black feedstock is located upstream of the plasma zone, (ii) the injection means for supplying the carbon black feedstock is located in the plasma zone, but preferably after the region where the plasma is generated, and / or (iii) the injection means for supplying the carbon black feedstock is located downstream of the plasma zone, preferably immediately after the plasma zone.

[0236] As described in the above method, the reactor may contain one or more injection means for the feedstock, preferably at least one injection means is installed upstream of the plasma zone and one injection means is installed downstream of the reaction zone.

[0237] Preferably, the reaction chamber is designed as a Laval nozzle, which includes a constriction where the plasma is generated. The use of a Laval nozzle has the advantage that the pressure can be reduced at a precise location to produce carbon black. The reaction chamber may be a tubular conduit.

[0238] The means for generating plasma is an arc plasma generator, a microwave plasma generator, a corona discharge plasma generator, or a dielectric barrier discharge (DBD) plasma generator, or a radio frequency (RF) plasma generator, preferably a microwave plasma generator. The plasma generator is generally installed outside the reaction chamber. The RF plasma generator and the microwave plasma generator are generally installed outside the reaction chamber. The type of plasma is not limited to a specific type, as is the plasma generator.

[0239] The means for generating plasma is preferably a microwave plasma generator. The microwave plasma generator should comprise a magnetron and a resonator. Furthermore, the microwave plasma generator may comprise a magnetron, a circulator, a coupler, a tuner, a waveguide such as a tapered waveguide, and a resonator. The microwave plasma generator may comprise a ring resonator circumferentially attached to the reaction chamber.

[0240] The microwave plasma generator may include a waveguide and a resonator such that microwave energy is applied to the plasma gas perpendicular to a central longitudinal axis of the reaction chamber.

[0241] The injection means for supplying the carbon black feedstock should be located upstream of the plasma zone and is a feed lance arranged coaxially with the central longitudinal axis of the reactor. The injection means for supplying the carbon black feedstock can be located upstream of the plasma zone and is a feed lance arranged coaxially with the central longitudinal axis of the reactor, and the injection means for supplying the carbon black feedstock is located in the plasma zone, but preferably after the area where the plasma is generated.

[0242] The inner lining of the reaction chamber comprises aluminium oxide, preferably the inner lining of the reaction chamber in the region of the plasma zone comprises aluminium oxide, preferably 90-100% by weight aluminium oxide, more preferably 95-100% by weight aluminium oxide, most preferably 98-100% by weight aluminium oxide. Aluminium oxide is able to withstand high temperatures, so that the production of carbon black can be carried out using high temperatures.

[0243] The reactor may further comprise a swirling element capable of swirling the plasma gas, the swirling element being mounted upstream of the reaction chamber. The swirling element may comprise vanes for inducing swirling in the plasma gas or may comprise injection means allowing tangential injection of the carbon black feedstock or the plasma gas. Preferably, the swirling element is present within a tubular conduit.

[0244] The reactor may further comprise a flow guide means connected upstream of the reaction chamber or upstream of the swirl element, the flow guide means being capable of receiving the plasma gas and flowing the plasma gas parallel to the central longitudinal axis of the reactor / reaction chamber. The flow guide means may comprise a cylinder with openings in its wall, the openings being substantially perpendicular, preferably perpendicular, to the central longitudinal axis of the reactor, the cylinder being connected to the tubular conduit and being disposed along the central longitudinal axis of the reactor.

[0245] The feed injection means is a feed lance and extends through the tubular conduit defining a passageway for the plasma gas by a gap between an inner surface of the tubular conduit and an outer surface of the feed lance, preferably the feed lance is disposed along the central longitudinal axis of the reactor, or the injection means is a lance and extends through the tubular conduit defining a passageway for the plasma gas by a gap between an inner surface of the tubular conduit and an outer surface of the lance, preferably the lance is disposed along the central longitudinal axis of the reactor.

[0246] Typically, the reactor further comprises a first and a second swirl element, the first swirl element being located closer to the reaction chamber, each of the swirl elements should individually comprise at least one vane, preferably a plurality of vanes, the plurality of vanes being preferably arranged rotationally symmetrically with respect to the central longitudinal axis of the reactor.

[0247] If the vanes have a continuously decreasing pitch along the flow direction, the gas will swirl in a right-handed rotation. It is particularly preferred that all vanes of a swirl element have either an increasing or decreasing pitch. In general, all vanes of each swirl element have either an increasing or decreasing pitch, such that the gas turns either to the left or to the right. A continuously increasing or decreasing pitch further avoids flow interruptions.

[0248] Each of the swirl elements is individually equipped with at least one vane, preferably a plurality of vanes, preferably at least one vane being inclined at an angle of from 10 to 70°, preferably from 15 to 60°, more preferably from 25 to 55°, most preferably from 25 to 50° to the central longitudinal axis of the reactor.

[0249] At least one vane should be inclined to the central longitudinal axis of the reactor in a plane containing the central longitudinal axis of the reactor and each transverse axis, where each transverse axis is perpendicular to the central longitudinal axis of the reactor and perpendicular to each lateral axis, where each lateral axis is perpendicular to the central longitudinal axis of the reactor and extends in the direction of the width of the respective vane, preferably the vane is inclined to the central longitudinal axis of the reactor in said plane at an angle of 10-70°, preferably 15-60°, more preferably 25-55°, most preferably 25-50°.

[0250] An alternative definition of the inclination of the vanes with respect to the central longitudinal axis of the tubular conduit and the reactor is that the length axis of the vanes is parallel to the central longitudinal axis of the reactor, and then the particular vanes are rotated by the above defined angles around their respective central lateral axes. An example of a simple vane is a plate, such as a metal plate, or a rectangular plate. This rectangular plate can be rotated by the above defined angles, such as the first and / or second angles.

[0251] By providing a series of two vanes, i.e. two swirl elements arranged in series, the swirl of the plasma gas can be induced in stages, with the result that the advantage is that no flow separation occurs.

[0252] Each of the aforementioned swirl elements (or vanes) is typically mounted on the inner surface of a tubular conduit or on the outer surface of a feed injection means such as a feed lance. Thus, depending on the particular mounting, a gap is formed between the swirl element (or vanes) and the inner surface of the tubular conduit or the outer surface of the feed injection means. The gap is preferably small, which ensures that a large proportion of the gas has to pass through the swirl element, providing swirled gas and further enhancing the technical effect. Furthermore, it is particularly advantageous for the swirl element (or vanes) to be mounted on the inner surface of the tubular conduit, since this can prevent backflow of gas. Mounting the swirl element (or vanes) on the outer surface of the feed injection means provides an advantageously simple construction.

[0253] The side of at least one vane facing the flow can have, in a plane containing the central longitudinal axis of the reactor and the respective transverse axes, a constant pitch and / or a continuously increasing or decreasing pitch along the flow direction relative to the central longitudinal axis of the reactor, where each transverse axis is perpendicular to the central longitudinal axis of the reactor and perpendicular to each lateral axis, and where each lateral axis is perpendicular to the central longitudinal axis of the reactor and extends in the direction of the width of the respective vane.

[0254] At least one swivel element may comprise a vane forming a continuous thread along the central longitudinal axis of the reactor, preferably the vane has 2 to 10 turns, for example 2 to 5 turns, preferably the continuous thread has different pitches, i.e. a first pitch and a second pitch, the second pitch being greater than the first pitch, and / or the continuous thread has a constant pitch, and / or the pitch of the continuous thread increases or decreases continuously.

[0255] At least one vane should have a planar or curved shape, or a combination thereof, and / or at least one vane has a pitch that increases or decreases continuously along the flow direction.

[0256] The first swirl element can have at least one vane inclined at a first angle relative to the central longitudinal axis of the reactor in a plane containing the central longitudinal axis of the reactor and each transverse axis, and the second swirl element can have at least one vane inclined at a second angle relative to the central longitudinal axis of the reactor in a plane containing the central longitudinal axis of the reactor and each transverse axis, where each transverse axis is perpendicular to the central longitudinal axis of the reactor and perpendicular to each lateral axis, and where each lateral axis is perpendicular to the central longitudinal axis of the reactor and perpendicular to each vane. extending in the direction of the width of the board, the first angle is greater than the second angle, preferably the first angle is in the range of 15-70°, e.g. 20-60°, 30-55°, 35-60°, 35-55°, or 40-50°, and / or the second angle is in the range of 10-60°, e.g. 10-55°, 15-50°, 20-45°, 20-40°, or 25-35°, and / or the difference of the first angle from the second angle is at least 5-40°, e.g. 5-30°, 8-25°, 5-20°, or 10-20°.

[0257] The at least one swivel element should be fixed to or integrally formed with the inner surface of the tubular conduit and / or the outer surface of the raw material lance, and the at least one swivel element is preferably replaceably fixed to the inner surface of the tubular conduit and / or the outer surface of the raw material lance.

[0258] The tubular conduit may further comprise an inlet funnel arranged before the turning element with respect to the flow direction, the diameter of the inlet funnel preferably continuously decreasing along the flow direction, preferably the diameter ratio of the maximum diameter to the minimum diameter of the inlet funnel being in the range of more than 1 to 3, for example 1.1 to 2 or 1.5 to 2.

[0259] Injecting the feedstock with a lance in the centre of the conduit has the advantage that the feedstock does not come into contact with the walls, which reduces the possibility of condensation if the tube has a lower temperature than the gas.

[0260] The feedstock injection means may comprise at least one injection opening and / or at least one nozzle, the at least one injection opening and / or the at least one nozzle being arranged substantially perpendicular to a central longitudinal axis of the reactor and / or arranged at an angle in the range of 70 to 90°, for example 75 to 89°, 80 to 88° to the central longitudinal axis of the reactor.

[0261] The reactor should further comprise a quench chamber downstream of the reaction chamber, the quench chamber preferably comprising a means for reducing the temperature by injecting a quenching medium into a flow path along the central longitudinal axis of the reactor or using a heat exchanger.

[0262] The carbon black can be separated from the gas by simple separation of the solids.

[0263] Further provided is a carbon black preferably produced by the process of the present invention using the reactor of the present invention.

[0264] The present invention will now be described with reference to the accompanying drawings, which do not limit the scope and area of ​​the present invention. The description provided is purely for the purposes of example and illustration. However, certain features illustrated in the drawings may be used to further limit the scope of the present invention and the claims.

[0265] A reactor according to the invention is generally represented by the numeral (100) in FIG. 1. The reactor of FIG. 1 (100) comprises a chamber (002) in which a plasma (004) is generated. The plasma generator of FIG. 1 is a microwave plasma generator (003), and the microwave radiation introduced into the chamber (002) is perpendicular to a direction along the central longitudinal axis of the reactor (101). The means of providing the plasma is not limited. For example, the plasma can be a radio frequency plasma, an arc plasma, and a microwave plasma. Furthermore, the microwave radiation can be provided perpendicular to the central longitudinal axis of the reactor. Thus, the microwave radiation for providing the plasma (004) in the reactor (100) can be provided from one direction, or a ring resonator can be used so that the microwave radiation is directed circumferentially into the reaction chamber (002).

[0266] The plasma (004) provided by microwave radiation is present in the reaction chamber (002) without contacting the refractory lining (005) of the reactor (100). In FIG. 1, the reactor chamber (002) is designed as a Laval nozzle. The Laval nozzle is a tube sandwiched in the middle that creates an asymmetric hourglass shape. It is used to accelerate the plasma gas to axial supersonic speed by converting the thermal energy of the flow into kinetic energy. However, the shape of the reaction chamber is not limited to the Laval nozzle design. It is also possible to provide tubular tubes with a constant inner diameter or tubular tubes with different diameters connected by or without a conical section.

[0267] The letters A, B, C, D indicate possible positions for the introduction of the carbon black feedstock (feedstock) (103). However, it is also possible that the plasma gas (102) already contains or is the carbon black feedstock (103), in which case no additional introduction of the feedstock (103) as indicated by A, B, C and D is necessary. The position A for introducing the carbon black feedstock can be a feedstock lance (A) located along the central longitudinal axis of the reactor (101). Said lance (A) is thus located upstream (prior to, before) the means for providing the plasma, for example a microwave generator (003), or upstream of the plasma (004). The feedstock can also be introduced at a position (B), which is also upstream of the plasma (004), for example via a nozzle (or injection nozzle). The nozzle at position (B) is arranged perpendicular to the central longitudinal axis (101) of the reactor. The position can be behind or in front of the drawing plane. This gives the opportunity to generate, accelerate or reduce the swirl. However, the nozzle at position (B) can inject the carbon black feedstock to induce or promote the swirl. It is also preferred that the feedstock is introduced directly into the plasma (004) according to position (C). The means for introducing the feedstock are therefore arranged downstream of the microwave radiation fed into the reactor chamber (002) and at a position where the plasma (004) is present. Position (B) indicates that the feedstock is introduced upstream of the microwave radiation fed into the reactor chamber (002) and upstream of the plasma. Preferably, the introduction of the feedstock is made according to position D, directly behind the plasma. The injection can be realized perpendicular to the reactor axis, in the drawing plane, behind the drawing plane or in front of the drawing plane. The injection can be split into several injection tubes. This setup is particularly preferred when the plasma gas (102) is swirled. It is preferred to combine the introduction of the feedstock from different positions. For example, a source material (103) is introduced upstream of the plasma (004) and a second source material (103) is introduced downstream of the microwave radiation provided into the reactor chamber (002). For example, the first source material is introduced at position (A) and the second source material is introduced at position (C).

[0268] The plasma gas (102) and feedstock (103) may be preheated before entering the reaction chamber (002). Preheating may be done electrically. It is particularly preferred that the plasma gas and / or feedstock are not heated by the combustion of a fuel.

[0269] FIG. 1 relates to a section of a reactor for the production of carbon black. It is desirable to have a quenching chamber downstream of the reaction chamber (002). Furthermore, it is possible to arrange a swirling element upstream of the reaction chamber (002) to introduce swirl into the plasma gas (102). Swirling of the plasma gas can thus provide a stable and uniform plasma that does not come into contact with the inner lining of the reaction chamber. Injection B can be upstream or downstream of the swirling element. However, it is also possible to use, for example, a ring resonator, so that the microwave radiation is stable and directed in the circumferential direction in the reaction chamber (002) without coming into contact with the inner lining of the reaction chamber (002).

[0270] The swirl element can be any suitable means for providing swirl to the plasma gas. The following figures show possible elements using vanes or fins to provide the desired swirl.

[0271] Note that the swivel elements shown in the following figures include a feed lance, however, if a feed lance is not used to provide the feedstock, the tubular conduit may be adapted accordingly as shown in FIG.

[0272] With reference to Figures 2 and 3, a section of a pivoting element in the xz plane (010) and a section of a pivoting element in the xy plane (011) are shown.

[0273] As mentioned above, the turning elements can include vanes inclined with respect to the flow direction of the reactor along the central longitudinal axis of the reactor. Figure 2 shows a view in the xz plane of a particular vane (092) attached to a feed lance (111) inside a tubular conduit (110). Alternatively, if no feed lance (111) is present, the vanes can be attached to the inside surface of the tubular conduit. The longitudinal axis of the feed lance (111) is coaxial with the central longitudinal axis of the reactor (101). The central longitudinal axis (101) of the reactor represents the x-axis of the plane in the coordinate system. The coordinate system is a Cartesian system. The z-axis and y-axis in the coordinate system depend on the particular vane (092) considered. The z-axis is the respective transverse axis (090) perpendicular to the central longitudinal axis (101) of the reactor and perpendicular to the respective lateral axis (091). The respective lateral axis (091) of the vanes (092) considered is the y-axis (091) in the coordinate system. The respective lateral axis (091) is perpendicular to the central longitudinal axis (101) of the reactor and extends in the direction of the width of the respective vane. In FIG. 3, the width of the vanes (094) considered and the y-axis (091) extending in the direction of the width of the vanes (094) are shown. For coordinate systems where different vane angles (or positions, alignments, rotations and / or inclinations) are considered, a different respective lateral axis (z-axis) (090) and respective lateral axis (091) (y-axis) for the vanes considered are used. In other words, the y-axis and the z-axis depend on the respective vane. Also, the direction of the vane length (longitude) (095) extends in the flow direction. The height of the vanes (093) is shown in FIG. 2. Preferably, the x values ​​increase or decrease in the flow direction, preferably increase.

[0274] With reference to Figures 4, 5, 6 and 7, sections of a tubular conduit including a feed lance and a swirl element are shown. The swirl element can be directly attached to the reaction chamber shown in Figure 1. In particular, Figure 4 shows a section (200a) of a tubular conduit including a feed lance and a swirl element connected to the outer surface of the feed lance. Figure 5 shows a section (200b) of a tubular conduit including an inlet funnel, a feed lance and a swirl element connected to the outer surface of the feed lance. Figure 6 shows a section (200c) of a tubular conduit including a feed lance and a swirl element connected to the inner surface of the tubular conduit. Figure 7 shows a section (200d) of a tubular conduit including an inlet funnel, a feed lance and a swirl element connected to the inner surface of the tubular conduit.

[0275] Again, the tubular conduit includes two swirl elements (113a and 113b or 114a and 114b) arranged along the central longitudinal axis (101) of the reactor. As mentioned above, Figures 4 and 5 show a tubular conduit (110) with swirl elements (113a, 113b) attached to the feed lance (111). In Figures 6 and 7, the swirl elements (114a, 114b) are attached to the inner wall of the tubular conduit (110). In Figures 5 and 7, an inlet funnel (150) is connected to the tubular conduit (110).

[0276] In these figures, the feed means is provided as a plurality of injection openings (250) circumferentially arranged around the outer wall of the feed lance, the injection openings (250) being capable of injecting the feed in a direction substantially perpendicular to the central longitudinal axis (101) of the reactor.

[0277] With reference to Figures 4 and 5, the vanes (112a) of the first swirl element (113a) and the vanes (112b) of the second swirl element (113b) are attached to the outer wall of the material lance (111) such that there is a gap (210) between the vanes and the inner surface of the tubular conduit. In Figures 6 and 7, the vanes (112a) of the first swirl element (114a) and the vanes (112b) of the second swirl element (114b) are attached to the outer wall of the material lance (111) such that there is a gap (211) between the vanes and the outer surface of the material lance. The size of each gap should be in the range of 0 mm to 10 cm, for example 0 mm to 10 cm, 0 mm to 1 cm, 0 mm to 5 mm, 0.1 mm to 10 cm, 1 mm to 1 cm, 1 mm to 5 mm, or 1 mm to 2 mm, as mentioned above. The gap is preferably as small as possible, ie 0 mm, so that most of the plasma gas swirls.

[0278] The distance (220) between the first and second swivel elements can be in the range of 0-300 cm, e.g., 1-300 cm, 1-200 cm, 1-100 cm, 1-70 cm, 10-90 cm, 10-60 cm, 15-40 cm. This distance can be 0 cm. The distance (230) between the first swivel element and the end of the tubular conduit connected to the reaction chamber can be in the range of 0-2 m, e.g., 0-1.5 m, 1 cm-1.5 m, 1 cm-1 m, 1 cm-60 cm, 10 cm-60 cm, 15 cm-40 cm, 5 cm-30 cm, or 20 cm-1 m.

[0279] The inner diameter of the tubular conduit (240) can be selected from 1 cm to 3 m, for example 2 cm to 3 m, 3 cm to 3 m, 2 cm to 10 cm, 13 cm to 1.5 m, 0.1 m to 2 m, 20 cm to 1 m, 30 cm to 1.5 m, 15 cm to 60 cm, or 15 cm to 90 cm, as already mentioned above. The inner diameter of the tubular conduit (240) has an influence on the flow rate of the plasma gas and should be adjusted depending on the size of the reactor.

[0280] The distance (260) between the first pivot element and the ingredient inlet may be in the range of 1 cm to 1.5 m, such as 2 cm to 1 m, 10 cm to 1 m, 20 cm to 1 m, or 30 cm to 1 m.

[0281] As can be seen from the above figures, the vanes (112a) of the first swirl element closest to the plasma zone (004) are inclined with respect to the central longitudinal axis (101) of the reactor, taking into account the above coordinate system. The first angle (290a) of the vanes of the first swirl element between the length axis (291a) of the vanes of the first swirl element and the central longitudinal axis (101) of the reactor is greater than the second angle (290b) of the vanes of the second swirl element between the length axis (291b) of the vanes of the second swirl element and the central longitudinal axis (101) of the reactor. It should be noted that the vanes are arranged on the feed lance (111) such that the plasma gas swirls counterclockwise as viewed in the flow direction. However, it is also in accordance with the invention if the plasma gas swirls clockwise as viewed in the flow direction. It is preferable that multiple swirl elements induce swirls in the same direction. Right-hand rotation can be obtained simply by orienting the vanes (112a, 112b) so that the opposite side of the vanes faces the plasma gas flow, e.g., downward at the same angle as shown in the figure. Nevertheless, it is desirable for all vanes and turning elements provided inside the same tubular conduit to induce swirl with the same rotation, e.g., left or right.

[0282] The position and arrangement of the vanes can also be described using functions in the coordinate system mentioned above, where the z-axis and y-axis in the coordinate system depend on the particular vane (092) being considered. In particular, the respective lateral axis (091) of each vane (092) is the y-axis (091) in the coordinate system. Each lateral axis (091) is perpendicular to the central longitudinal axis (101) of the reactor and extends in the direction of the width of each vane. The z-axis is the respective lateral axis (090) perpendicular to the central longitudinal axis (101) of the reactor and perpendicular to each lateral axis (091). In this Cartesian coordinate system, the x-axis and the z-axis are considered for each vane. The origin in this Cartesian coordinate system can be at a position on the surface of the vane adjacent to the feed lance or conduit.

[0283] The vanes of Figures 1-7 have regions of constantly increasing or decreasing pitch, except for the rounded corners / edges, so that the side of the vane facing the plasma gas flow can be described by a function such as f(x)=(-)n*x, where n is the pitch and the x-axis is represented by the central longitudinal axis (101) of the reactor. The word "(-)" in the formula refers to the alternative negative sign indicating a decreasing pitch. Thus, the minus sign is optional. A continuously increasing or decreasing pitch can be described by a function such as f(x)=(-)x m (or f(x)=(-)n*x m ), where m can be selected from greater than 1 and less than or equal to 10, e.g., 2-10, 1-5, 1-3, 1.1-5, or 2-3. The derivative of the function at a particular point x reveals the pitch of the vane at this location. The function can be shifted in the x, y, and z directions, e.g., f(x)=(-)n*(x+b) m where the function shifts in the x-direction. The pitch of vanes with constant pitch or regions of constant pitch is preferably in the range of 0.09 to 10, 0.17 to 6, 0.26 to 6, 0.26 to 3, or 0.17 to 1.75 without sign (i.e. in absolute value). The maximum pitch of vanes, such that, except for the regions where the pitch is constant, for example, the pitch is constantly increasing or decreasing, is preferably in the range of 0.09 to 10, 0.17 to 6, 0.26 to 6, 0.26 to 3, 0.17 to 2.74, 0.26 to 1.73, 0.46 to 1.42, 0.46 to 1.2, or 0.17 to 1.75 without sign (i.e. in absolute value). Since the maximum pitch is defined in absolute value, the maximum pitch represents continuously increasing and decreasing pitches.

[0284] The dimensions of the vanes of each pivoting element (113a and 113b or 114a and 114b) may be the same or different. For example, the length of the vanes (095) (270) of the first pivoting element may be in the range of 1 cm to 3 m, such as 5 cm to 2 m, 10 cm to 1 m, 15 cm to 1 m, 20 cm to 90 cm, 25 cm to 1 m, 30 to 60 cm, 40 cm to 1.5 m, or 35 cm to 3 m. The length of the vanes (095) (271) of the second pivoting element may be in the range of 1 cm to 3 m, such as 5 cm to 2 m, 10 cm to 1 m, 15 cm to 1 m, 20 cm to 90 cm, 25 cm to 1 m, 30 to 60 cm, 40 cm to 1.5 m, or 35 cm to 3 m. The width (094) (280) of the vanes of the first pivoting element can be in the range of 0.24 cm to 2.9 m, such as 1 cm to 2.5 m, 9 cm to 2.5 m, 10 cm to 2 m, 20 cm to 2 m, 8 cm to 1 m, 12 cm to 1.4 m, 0.1 m to 2 m, 19 cm to 1 m, 30 cm to 1.5 m, 14 cm to 60 cm, 14 to 59, or 14 cm to 89 cm. The width of the vanes (094) (281) of the second pivoting element can be in the range of 4 cm to 2.9 m, e.g., 5 cm to 2.5 m, 9 cm to 2.5 m, 10 cm to 2 m, 20 cm to 2 m, 8 cm to 1 m, 12 cm to 1.4 m, 0.1 m to 2 m, 19 cm to 1 m, 30 cm to 1.5 m, 14 cm to 60 cm, 14 to 59, or 14 cm to 89 cm. In particular, the width of the vanes (094) of the swivel elements (280, 281) should be selected so that the oblique gap between the free part of at least one swivel element and the inner surface of the tubular conduit or the outer surface of the material lance to which the swivel element is not attached or integrally formed is as small as possible, being less than 0 mm to 10 cm as defined above, for example 0 mm to 10 cm, 0 mm to 1 cm, 0 mm to 5 mm, 0.1 mm to 10 cm, 1 mm to 1 cm, 1 mm to 5 mm, or 1 mm to 2 mm. The shape and dimensions of the vanes of a particular swivel element are preferably the same. According to the invention, three or more swivel elements are also desirable, the dimensions of the vanes of the further swivel elements being able to be selected from the dimensions mentioned above.

[0285] With reference to Figures 8, 9 and 10, sections of a swirl element are illustrated. In particular, Figure 8 shows a section of a swirl element (300a) having two regions of constant pitch with a smooth transition. Figure 9 shows a section of a swirl element (300b) having two regions of constant pitch with a sharp transition. Figure 10 shows a section of a swirl element (300c) having a continuously decreasing pitch. The flow direction is indicated by arrows showing the passage of the plasma gas (102). The region of pitch refers to the side of the vane facing the flow.

[0286] FIG. 8 shows a swirl element with a first region of vanes (310) with a first constant pitch and a second region of vanes (320) with a second constant pitch. Alternatively, these two regions of pitch can be described as two swirl elements attached to each other at a distance of 0 mm so that there is no gap between the vanes. The second region of vanes (320) with a second constant pitch comprises a region of constant pitch and a length axis (330) of the second region of vanes with a second constant pitch. The angle (340) of the length axis of the second region of vanes of the first swirl element with a second constant pitch to the central longitudinal axis of the reactor can be the same as defined above, i.e. an angle of 10 to 70°, preferably 15 to 60°, more preferably 25 to 55°, most preferably 25 to 50°. The pitch of the second region (320) of the vanes having the second constant pitch can be in the range, without sign (i.e., absolute value), of 0.09 to 10, 0.17 to 6, 0.26 to 6, 0.26 to 3, 0.17 to 2.74, 0.26 to 1.73, 0.46 to 1.42, 0.46 to 1.2, or 0.17 to 1.75.

[0287] FIG. 9 differs from FIG. 8 in that a first region of the vanes (310) having a first constant pitch and a second region of the vanes (320) having a second constant pitch are joined at a sharp angle.

[0288] The turning element (300c) shown in Figure 10 has a continuously decreasing pitch for the side of the vane facing the plasma gas flow. Taking into account the flow direction of the plasma gas (102), the pitch is constantly decreasing. The function describing the side facing the plasma gas and having a constantly decreasing pitch is f(x) = n*(-x). 2 The maximum pitch of the vanes (331) is preferably in the range of 0.09-10, 0.17-6, 0.26-6, 0.26-3, 0.17-2.74, 0.26-1.73, 0.46-1.42, 0.46-1.2, or 0.17-1.75, without sign (i.e., in absolute value). Since the maximum pitch is defined in absolute value, it represents continuously increasing and decreasing pitch. It should be noted that the maximum pitch and angle of the vanes are involved in the degree of turning or spinning.

[0289] Referring to Figures 11 and 12, a section of a feed lance containing three swirl elements with different arrangements (400a, 400b) is shown.

[0290] In particular, these figures reveal different possible configurations of the swirl elements attached to the feed lance. It is clear that these swirl elements can also be attached to the inner wall of the tubular conduit. Furthermore, different arrangements of the different swirl elements are possible.

[0291] As can be seen in Fig. 11, three pivot elements are arranged in series. The first pivot element, which is located closest to the plasma zone (004), includes a first region of vanes (310a) having a first pitch and a second region of vanes (320a) having a second pitch. The second pivot element, which is located between the first and third pivot elements (113c), includes a first region of vanes (310b) having a first pitch and a second region of vanes (320b) having a second pitch. The third pivot element (113c) includes a first region of vanes (310c) having a first pitch and a second region of vanes (320c) having a second pitch. The angles (340a, 340b, and 340c) between each length axis (330a, 330b, and 330c) of the second region of each vane having a second pitch and the central longitudinal axis (101) of the reactor continuously increase in the flow direction, and as a result, the degree of swirl also continuously increases.

[0292] In FIG. 12, three different types of swirl elements are attached to the feed lance. The first swirl element includes vanes with a continuously increasing pitch (311) with a maximum pitch (331) at the end of the vanes. The second swirl element (112b) has a constant pitch and is inclined at a specific angle (290b) with respect to the length axis (291b) of the vanes of the second swirl element and the central longitudinal axis (101) of the reactor. The third swirl element includes a first region (310c) of vanes with a first pitch and a second region (320c) of vanes with a second pitch. Again, the pitch and / or angle increase continuously in the flow direction.

[0293] FIG. 13 shows a multi-view projection of a swivel element with one vane attached to the outer surface of a feed lance (112) in a tubular conduit (110). It is possible for multiple vanes to be attached to the feed lance. Preferably, multiple vanes are attached to the feed lance such that each vane at least partially overlaps at least a second vane. The vanes in FIG. 13 have a constant pitch (311), although other vane configurations as discussed above can be used as desired. Additionally, vanes can also be attached to the inner surface of the tubular conduit (110), particularly if no feed lance is present.

[0294] FIG. 14 shows a tubular conduit (110) without a feed lance.

[0295] It will be understood that various modifications can be made and many changes can be made in the preferred embodiment without departing from the principles of the invention.

[0296] 1. A method for producing carbon black, preferably using the reactor described in any one of embodiments 35 to 60, comprising the steps of: (a) injecting a plasma gas into a carbon black reactor; (b) subjecting a plasma gas to a plasma zone (or plasma torch) to obtain a product mixture comprising carbon black; (c) quenching the product mixture; (d) separating the carbon black from the product mixture, wherein (i) the plasma gas comprises or consists of a carbon black feedstock; (ii) the carbon black feedstock is injected into the plasma gas upstream of the plasma zone; (iii) the carbon black feedstock is injected into the plasma zone, but preferably after the region where the plasma is generated; and / or (iv) the carbon black feedstock is injected into the plasma gas downstream of the plasma zone.

[0297] 2. 2. The method of embodiment 1, wherein the plasma is generated in response to excitation of the plasma gas by microwave energy, the plasma is generated in response to excitation of the plasma gas by an electric arc, the plasma is generated in response to excitation of the plasma gas by a corona discharge, the plasma is generated in response to excitation of the plasma gas by a dielectric barrier discharge (DBD), and / or the plasma is generated in response to excitation of the plasma gas by radio frequency energy, preferably the plasma is generated in response to excitation of the plasma gas by microwave energy.

[0298] 3. 3. The method of claim 1 or 2, wherein the plasma gas is preheated prior to subjecting the gas to the plasma zone, preferably the plasma gas is preheated to a temperature of 100-1600°C, e.g., 300-1400°C, 400-1200°C, 500-1000°C, 600-1500°C, 100-300°C, 200-400°C, 300-500°C, 400-600°C, 1000-1500°C, or 700-900°C.

[0299] 4. The method of any one of the preceding aspects, wherein the plasma gas comprising the carbon black raw material has a temperature of (i) 260 to 920 K, preferably 269 to 700 K, (ii) 290 to 340 K, (iii) 340 to 390 K, (iv) 390 to 440 K, (v) 440 to 490 K, (vi) 490 to 540 K, (vii) 540 to 590 K, (viii) 590 to 640 K, (ix) 640 to 690 K, or (x) 690 to 740 K.

[0300] 5. 5. The method of any one of the preceding aspects, wherein the plasma gas comprises or is hydrogen and / or HO (preferably H), and / or the plasma gas comprises or is a carbon black feedstock.

[0301] 6. The method of any one of the preceding aspects, wherein (A) the plasma gas and the carbon black feedstock are mixed prior to subjecting the gases to the plasma zone, and / or (B) the plasma gas comprises or consists of a material having a critical temperature below a temperature of the gas (plasma gas mixture), and / or (C) the carbon black feedstock (preferably the first carbon black feedstock) comprises or consists of a material having a critical temperature above a temperature of the gas (plasma gas mixture).

[0302] 7. The method of any one of the preceding embodiments, wherein the plasma gas and the carbon black feedstock are mixed in a molar ratio such that the carbon black feedstock does not form droplets (or condense or is not in the liquid phase) in the carbon black reactor, prior to subjecting the gases to the plasma zone.

[0303] 8. The method of any one of the preceding aspects, wherein the material having a critical temperature less than the temperature of the gas is present in the plasma gas with the carbon black raw material in a molar ratio such that the carbon black raw material does not form droplets (or does not condense or is not in the liquid phase) in the carbon black reactor prior to subjecting the gas to the plasma zone.

[0304] 9. The plasma gas and the carbon black feedstock (plasma gas and carbon black mixture) are mixed prior to providing the gases to the plasma zone, wherein the molar percentage of the plasma gas and / or material having a critical temperature below a temperature of the gas, based on the total molar amount of the plasma gas including the carbon black feedstock, is (i) 1 to 20 mol % when the normal boiling point and / or final normal boiling point of the carbon black raw material is 270 to 300 K and the temperature of the gas mixture is 250 to 290 K; (ii) 30 to 95 mol % when the normal boiling point of the carbon black raw material is more than 300 to 350 K and the temperature of the gas mixture is 270 to 300 K; (iii) 50 to 80 mol % when the normal boiling point and / or final normal boiling point of the carbon black raw material is more than 350 to 400 K and the temperature of the gas mixture is 340 to 360 K; (iv) 50 to 75 mol% when the normal boiling point and / or final normal boiling point of the carbon black raw material is more than 400 to 450 K and the temperature of the gas mixture is 390 to 420 K; (v) 40 to 65 mol % when the normal boiling point and / or final normal boiling point of the carbon black raw material is more than 450 to 500 K and the temperature of the gas mixture is 440 to 460 K; (vi) 20 to 65 mol % when the normal boiling point and / or final normal boiling point of the carbon black raw material is more than 500 to 550 K and the temperature of the gas mixture is 490 to 520 K; (vii) 20 to 55 mol % when the normal boiling point and / or final normal boiling point of the carbon black feedstock is greater than 550 to 610 K and the temperature of the gas mixture is between 540 and 570 K; or (viii) 30 to 65 mol% when the normal boiling point and / or final normal boiling point of the carbon black raw material is greater than 610 to 670 K and the temperature of the gas mixture is 590 to 630 K; 13. The method of any one of the preceding aspects.

[0305] 10. The plasma gas containing the carbon black feedstock may be subjected to the steps of: (i) when the final normal boiling point of the carbon black raw material is between 270 and 300 K and the temperature of the gas mixture is between 250 and 290 K, it contains between 1 mol % and 20 mol % of a material having a critical temperature lower than the temperature of the gas; (ii) when the final normal boiling point of the carbon black raw material is greater than 300 to 350 K and the temperature of the gas mixture is between 270 and 290 K, it contains 30 to 95 mol % of a material having a critical temperature less than the temperature of the gas; (iii) when the final normal boiling point of the carbon black raw material is greater than 350 to 400 K and the temperature of the gas mixture is between 340 and 360 K, it contains 50 to 80 mol % of a material having a critical temperature less than the temperature of the gas; (iv) when the final normal boiling point of the carbon black raw material is greater than 400 to 450 K and the temperature of the gas mixture is between 390 and 420 K, it contains 50 to 75 mol % of a material having a critical temperature less than the temperature of the gas; (v) when the final normal boiling point of the carbon black raw material is greater than 450 to 500 K and the temperature of the gas mixture is between 440 and 460 K, it contains 40 to 65 mol % of a material having a critical temperature less than the temperature of the gas; (vi) when the final normal boiling point of the carbon black raw material is greater than 500 to 550 K and the temperature of the gas mixture is between 490 and 520 K, it contains 20 to 65 mol % of a material having a critical temperature less than the temperature of the gas; (vii) When the normal final boiling point of the carbon black raw material is greater than 550 to 610 K and the temperature of the gas mixture is between 540 and 570 K, it contains between 20 and 55 mol % of a material having a critical temperature less than the temperature of the gas; or (viii) when the final normal boiling point of the carbon black raw material is greater than 610 to 670 K and the temperature of the gas mixture is between 590 and 630 K, it contains 30 to 65 mol % of a material having a critical temperature less than the temperature of the gas; 6. The method of any one of the preceding aspects, wherein the material comprises a plasma gas, preferably such as hydrogen, or a carbon black feedstock.

[0306] 11. The plasma gas and the carbon black feedstock are mixed prior to subjecting the gases to the plasma zone, and the mole percent of the plasma gas, the mole percent of the plasma gas having a critical temperature below the temperature of the gas, and / or the mole percent of the material having a critical temperature below the temperature of the gas (preferably the mole percent of the material having a critical temperature below the temperature of the gas) is based on the total molar amount of the plasma gas including the carbon black feedstock, and is greater than or equal to x. dilutant Greater than x dilutant The method of any one of the preceding embodiments, wherein is calculated according to formula (V):

number

[0307] 12. The plasma gas and the carbon black feedstock are mixed prior to subjecting the gases to the plasma zone, and the mole percent of the plasma gas, the mole percent of the plasma gas having a critical temperature below the temperature of the gas, and / or the mole percent of the material having a critical temperature below the temperature of the gas (preferably the mole percent of the material having a critical temperature below the temperature of the gas) is based on the total molar amount of the plasma gas including the carbon black feedstock, and is greater than or equal to x. dilutant Greater than x dilutant The method of any one of the preceding aspects, wherein is calculated according to formula (IX):

number

number

[0308] 13. The plasma gas and the carbon black feedstock are mixed prior to subjecting the gases to the plasma zone, and the mole percent of the plasma gas, the mole percent of the plasma gas having a critical temperature below the temperature of the gas, and / or the mole percent of materials having a critical temperature below the temperature of the gas (preferably the mole percent of the plasma gas having a critical temperature below the temperature of the gas) is based on the total molar amount of the plasma gas including the carbon black feedstock, and is greater than or equal to x. dilutant Greater than x dilutant The method of any one of the preceding embodiments, wherein is calculated according to formula (XVII):

number

number

[0309] 14. The carbon black feedstock, which is mixed with the gas prior to subjecting it to the plasma zone, is analyzed by distillation of the carbon black feedstock, the carbon black feedstock being separated by distillation into 10 samples / fractions (preferably 10 samples / fractions each having 10% by volume based on the total amount of samples analyzed), and the temperature at which the last drop of each sample / fraction is distilled is the respective boiling point T of the sample / fraction. b,i [K], and preferably the mole fraction is calculated for each sample / fraction.

[0310] 15. The plasma gas and the carbon black feedstock are mixed prior to subjecting the gases to the plasma zone, and the mole percent of the plasma gas, the mole percent of the plasma gas having a critical temperature below the temperature of the gas, and / or the mole percent of materials having a critical temperature below the temperature of the gas (preferably the mole percent of the plasma gas having a critical temperature below the temperature of the gas) is based on the total molar amount of the plasma gas including the carbon black feedstock, and is greater than or equal to x. dilutant Greater than x dilutant The method of any one of the preceding embodiments, wherein is calculated according to formula (V), formula (IX) and / or formula (XVII):

number

number

number

number

number

[0311] 16. 5. The method of any one of the preceding aspects, wherein the pressure in the plasma zone and / or the pressure of the plasma gas in the plasma zone is between 0.1 and 1.3 bar, such as between 0.1 and 1.2 bar, 0.1 and 1.1 bar, 0.1 and 1 bar, 0.2 and 1 bar, 0.2 and less than 1 bar, 0.1 and 0.5 bar, 0.2 and 0.9 bar, 0.3 and 0.8 bar, or 0.3 and 0.5 bar, and preferably the pressure upstream of the plasma zone and / or the pressure of the plasma gas upstream of the plasma zone is higher than the pressure in the plasma zone and / or the pressure of the plasma gas in the plasma zone.

[0312] 17. 5. The method of any one of the preceding aspects, wherein the pressure upstream of the plasma zone and / or the pressure of the plasma gas upstream of the plasma zone is between 0.1 and 3 bar, such as between 0.2 and 2.6 bar, 0.5 and 2.5 bar, 0.9 and 2.2 bar, 1 and 2 bar, 1.5 and 2 bar, 1.6 and 3 bar, 1 and 1.5 bar, or 1.1 and 1.4 bar, preferably the pressure upstream of the plasma zone and / or the pressure of the plasma gas upstream of the plasma zone is higher than the pressure in the plasma zone and / or the pressure of the plasma gas in the plasma zone.

[0313] 18. 4. The method of any one of the preceding aspects, wherein the reaction chamber is designed as a Laval nozzle such that the gas flow has a velocity of less than 1 Ma before the constriction of the Laval nozzle, a velocity of 1 Ma at the constriction of the Laval nozzle, and a velocity of more than 1 Ma after the constriction of the Laval nozzle, and the plasma is generated at the constriction of the Laval nozzle.

[0314] 19. 4. The method of any one of the preceding aspects, wherein the reaction chamber is designed as a Laval nozzle, and the plasma is generated at a constriction of the Laval nozzle.

[0315] 20. 4. The method of any one of the preceding aspects, wherein the reaction chamber is designed as a Laval nozzle such that the gas flow has a velocity of less than 1 Ma before the constriction of the Laval nozzle, has a velocity of less than 1 Ma at the constriction of the Laval nozzle, and has a velocity of less than 1 Ma after the constriction of the Laval nozzle, and the plasma is generated at the constriction of the Laval nozzle, and wherein the gas flow velocity at the constriction is greater than before the constriction and the gas flow velocity after the constriction is greater than at the constriction.

[0316] twenty one. The method of any one of the preceding aspects, wherein the plasma gas is swirl prior to subjecting the gas to the plasma zone, preferably the plasma gas has a swirl number of 0.2-1.2, preferably 0.3-0.8, more preferably 0.5-0.7, even more preferably 0.55-0.65.

[0317] twenty two. The method of any one of the preceding aspects, wherein the plasma is generated in response to excitation of a plasma gas with microwave energy, thereby generating a plasma zone, and wherein the microwave radiation is applied perpendicular to a central longitudinal axis of the reactor or a flow direction of the plasma gas, and / or the microwave radiation is applied radially and circumferentially relative to the central longitudinal axis of the reactor or a flow direction of the plasma gas.

[0318] twenty three. 5. The method of any one of the preceding aspects, wherein the plasma gas further comprises HO, and / or silica is injected into the product mixture after (downstream from) the plasma zone.

[0319] twenty four. 5. The method of any one of the preceding aspects, wherein the temperature in the plasma zone is between 1200-5000K, e.g., 1300-4000K, 1300-3000K, 1400-3500K, 1300-2500K, 1300-2000K, 1300-1800K, or 1500-3000K.

[0320] twenty five. 6. The method of any one of the preceding embodiments, wherein the carbon black raw material is preferably liquid at 23° C. and 1 atm.

[0321] 26. 6. The method of any one of the preceding aspects, wherein the carbon black feedstock comprises a non-aromatic feedstock, an aromatic feedstock, an aliphatic feedstock, an aliphatic oil, a sustainable feedstock, a renewable carbon black feedstock, and / or a bio-based feedstock.

[0322] 27. 5. The method of any one of the preceding aspects, wherein the plasma gas preferably comprises or is hydrogen and is derived from pyrolysis of a carbon black feedstock.

[0323] 28. The method of any one of the preceding aspects, wherein the method further comprises separating the carbon black and H2 present in the product mixture and / or providing the separated H2 as a plasma feed gas.

[0324] 29. 6. The method of any one of the preceding aspects, wherein the plasma feed gas or hot plasma feed gas is not heated by combustion of a fuel.

[0325] 30. A method according to any one of the preceding aspects, wherein a first carbon black feedstock is injected into the plasma gas prior to subjecting the plasma gas to the plasma zone and a second carbon black feedstock is injected into the plasma zone, but preferably after the region where the plasma is generated, preferably the first carbon black feedstock is the carbon black feedstock defined in any one of the preceding aspects.

[0326] 31. The method of any one of the preceding aspects, wherein a first carbon black feedstock is injected into the plasma gas prior to subjecting the plasma gas to the plasma zone and a second carbon black feedstock is injected immediately after the plasma zone, preferably the first carbon black feedstock is the carbon black feedstock defined in any one of the preceding aspects.

[0327] 32. The carbon black produced is (a) 40~140m 2 / g, preferably 60 to 130m 2 / g, more preferably 65 to 120m 2 / g, and an oil absorption (OAN) measured according to ASTM D2414-18 in the range of 40 to 200 mL / 100 g, preferably 60 to 180 mL / 100 g, more preferably 80 to 160 mL / 100 g; (b) 40~120m 2 / g, preferably 50 to 100m 2 / g, more preferably 65 to 90m 2 / g, and an oil absorption (OAN) measured according to ASTM D2414-18 in the range of 40 to 180 mL / 100 g, preferably 50 to 160 mL / 100 g, more preferably 70 to 150 mL / 100 g; (c) 200~600m 2 / g, preferably 250 to 500m 2 / g, more preferably 300 to 450m 2and / or an STSA surface area, measured according to ASTM D6556-17, in the range of 50 to 150 mL / 100 g, preferably 60 to 120 mL / 100 g, more preferably 70 to 100 mL / 100 g, and / or an oil absorption number (OAN), measured according to ASTM D2414-18, in the range of 50 to 150 mL / 100 g, preferably 60 to 120 mL / 100 g, more preferably 70 to 100 mL / 100 g. (d) 140~210m 2 / g, preferably 150 to 200m 2 / g, more preferably 160 to 190m 2 and an oil absorption number (OAN) measured according to ASTM D2414-18 in the range of 100 to 200 mL / 100 g, preferably 110 to 170 mL / 100 g, more preferably 120 to 160 mL / 100 g. 13. The method of any one of the preceding aspects.

[0328] 33. The method of any one of the preceding aspects, wherein 60-100% by weight, preferably 90-100% by weight, more preferably 97-100% by weight, even more preferably 99-100% by weight, and most preferably 99.9-100% by weight of the carbon black raw material is composed of compounds containing at least 5 carbon atoms.

[0329] 34. The plasma gas flow rate (or hydrogen gas flow rate) is 10 Nm 3 / h~10000Nm 3 / h, e.g. 20Nm 3 / h~5000Nm 3 / h, 30Nm 3 / h~2000Nm 3 / h, 40Nm 3 / h~1000Nm 3 / h, or 50 Nm 3 / h~500Nm 3

[0036] The method of any one of the preceding embodiments, wherein

[0330] 35. 1. A reactor for producing carbon black, preferably according to any one of the preceding embodiments, having a flow path along a central longitudinal axis of the reactor, comprising: (A) a reaction chamber; (B) an injection means for supplying carbon black feedstock; and (C) means for generating a plasma within the reaction chamber, thereby forming a plasma zone; wherein (i) the injection means for supplying the carbon black feedstock is located upstream of the plasma zone; (ii) the injection means for supplying the carbon black feedstock is located in the plasma zone, but preferably after the region where the plasma is generated; and / or (iii) the injection means for supplying the carbon black feedstock is located downstream of the plasma zone, preferably immediately after the plasma zone.

[0331] 36. 36. The reactor of embodiment 35, wherein the reaction chamber is designed as a Laval nozzle including a constriction in which the plasma is generated.

[0332] 37. 37. The reactor of embodiment 35 or 36, wherein the reaction chamber is a tubular conduit.

[0333] 38. 38. The reactor of any one of aspects 35 to 37, wherein the means for generating plasma is an arc plasma generator, a microwave plasma generator, a radio frequency (RF) plasma generator, a corona discharge plasma generator, or a dielectric barrier discharge (DBD) plasma generator, preferably a microwave plasma generator.

[0334] 39. The reactor of any one of aspects 35 to 38, wherein the means for generating plasma is a microwave generator, and the microwave generator is located outside the reaction chamber.

[0335] 40. The reactor of any one of aspects 35 to 39, wherein the means for generating plasma is a microwave plasma generator, the microwave plasma generator comprising a ring resonator circumferentially mounted in the reaction chamber.

[0336] 41. The reactor of any one of aspects 35 to 40, wherein the means for generating plasma is a microwave plasma torch, and the microwave plasma generator includes a waveguide and a resonator such that microwave energy is applied to the plasma gas perpendicular to the central longitudinal axis of the reaction chamber.

[0337] 42. 42. The reactor of any one of aspects 35 to 41, wherein the injection means for supplying the carbon black feedstock is a feed lance located upstream of the plasma zone and aligned coaxially with a central longitudinal axis of the reactor.

[0338] 43. 43. The reactor of any one of aspects 35 to 42, wherein the injection means for supplying the carbon black feedstock is a feed lance located upstream of the plasma zone and arranged coaxially with the central longitudinal axis of the reactor, and the injection means for supplying the carbon black feedstock is located in the plasma zone, but preferably after the region where the plasma is generated.

[0339] 44. 44. The reactor according to any one of aspects 35 to 43, wherein the inner lining of the reaction chamber comprises aluminium oxide, preferably the inner lining of the reaction chamber in the region of the plasma zone comprises aluminium oxide, preferably 90 to 100% by weight of aluminium oxide, more preferably 95 to 100% by weight of aluminium oxide, most preferably 98 to 100% by weight of aluminium oxide.

[0340] 45. The reactor of any one of embodiments 35 to 44, further comprising a swirling element capable of swirling the plasma gas, the swirling element being mounted upstream of the reaction chamber.

[0341] 46. 46. ​​The reactor of any one of aspects 35 to 45, wherein the reactor further comprises a flow guiding means connected upstream of the reaction chamber or upstream of the swirl element, the flow guiding means capable of receiving the plasma gas and flowing the plasma gas parallel to a central longitudinal axis of the reactor.

[0342] 47. 47. The reactor of embodiment 46, wherein the flow guide means can comprise a cylinder having an opening in a wall thereof, the opening being substantially perpendicular, preferably perpendicular, to a central longitudinal axis of the reactor, the cylinder being connected to the tubular conduit and disposed along the central longitudinal axis of the reactor.

[0343] 48. 48. The reactor of any one of aspects 35-47, wherein the feed injection means is a feed lance and extends through the tubular conduit defining a passageway for the plasma gas by a gap between an inner surface of the tubular conduit and an outer surface of the feed lance, preferably the feed lance is disposed along the central longitudinal axis of the reactor; or the injection means is a lance and extends through the tubular conduit defining a passageway for the plasma gas by a gap between an inner surface of the tubular conduit and an outer surface of the lance, preferably the lance is disposed along the central longitudinal axis of the reactor.

[0344] 49. The reactor of any one of embodiments 35 to 48, wherein the reactor further comprises first and second swirl elements, the first swirl element being positioned closer to the reaction chamber.

[0345] 50. 50. The reactor of any one of aspects 35 to 49, wherein each of the turning elements comprises at least one vane, preferably a plurality of vanes, each of which is preferably arranged rotationally symmetrically with respect to a central longitudinal axis of the reactor.

[0346] 51. 51. The reactor according to any one of aspects 35 to 50, wherein each turning element individually comprises at least one vane, preferably a plurality of vanes, preferably at least one vane being inclined at an angle of from 10 to 70°, preferably from 15 to 60°, more preferably from 25 to 55°, most preferably from 25 to 50° with respect to a central longitudinal axis of the reactor.

[0347] 52. 52. The reactor according to any one of aspects 35 to 51, wherein at least one vane is inclined to the central longitudinal axis of the reactor in a plane containing the central longitudinal axis of the reactor and each transverse axis, wherein each transverse axis is perpendicular to the central longitudinal axis of the reactor and perpendicular to each lateral axis, and each lateral axis is perpendicular to the central longitudinal axis of the reactor and extends in the direction of the width of the respective vane, and preferably the vane is inclined to the central longitudinal axis of the reactor in said plane at an angle of 10 to 70°, preferably 15 to 60°, more preferably 25 to 55°, and most preferably 25 to 50°.

[0348] 53. 53. The reactor of any one of aspects 35 to 52, wherein a side of at least one vane facing the flow has, in a plane containing the central longitudinal axis of the reactor and the respective transverse axes, a constant pitch and / or a continuously increasing or decreasing pitch along the flow direction relative to the central longitudinal axis of the reactor, wherein each transverse axis is perpendicular to the central longitudinal axis of the reactor and perpendicular to each lateral axis, and each lateral axis is perpendicular to the central longitudinal axis of the reactor and extends in the direction of the width of the respective vane.

[0349] 54. 54. The reactor of any one of aspects 35 to 53, wherein at least one turning element comprises a vane forming a continuous thread along a central longitudinal axis of the reactor, preferably the vane has 2 to 10 turns, such as 2 to 5 turns, and preferably the continuous thread has different pitches, i.e. a first pitch and a second pitch, the second pitch being greater than the first pitch, and / or the continuous thread has a constant pitch, and / or the pitch of the continuous thread increases or decreases continuously.

[0350] 55. 55. The reactor of any one of aspects 35 to 54, wherein at least one vane has a planar or curved shape, or a combination thereof, and / or at least one vane has a pitch that increases or decreases continuously along the flow direction.

[0351] 56. The first pivoting element can have at least one vane inclined at a first angle relative to the central longitudinal axis of the reactor in a plane containing the central longitudinal axis of the reactor and each transverse axis, and the second pivoting element can have at least one vane inclined at a second angle relative to the central longitudinal axis of the reactor in a plane containing the central longitudinal axis of the reactor and each transverse axis, where each transverse axis is perpendicular to the central longitudinal axis of the reactor and perpendicular to each lateral axis, and where each lateral axis is perpendicular to the central longitudinal axis of the reactor and extends in the direction of the width of each vane. 56. The reactor according to any one of aspects 35 to 55, wherein the first angle is greater than the second angle, preferably the first angle is in the range of 15 to 70°, such as 20 to 60°, 30 to 55°, 35 to 60°, 35 to 55°, or 40 to 50°, and / or the second angle is in the range of 10 to 60°, such as 10 to 55°, 15 to 50°, 20 to 45°, 20 to 40°, or 25 to 35°, and / or the difference of the first angle from the second angle is at least 5 to 40°, such as 5 to 30°, 8 to 25°, 5 to 20°, or 10 to 20°.

[0352] 57. 57. The reactor of any one of aspects 35 to 56, wherein the at least one swirl element is fixed to or integrally formed with an inner surface of the tubular conduit and / or an outer surface of the feed lance, and the at least one swirl element is preferably replaceably fixed to the inner surface of the tubular conduit and / or the outer surface of the feed lance.

[0353] 58. 58. The reactor of any one of aspects 35 to 57, wherein the tubular conduit further comprises an inlet funnel located before the turning element with respect to the flow direction, the diameter of the inlet funnel preferably continuously decreasing along the flow direction, and preferably the diameter ratio of the maximum diameter to the minimum diameter of the inlet funnel is in the range of more than 1 to 3, such as 1.1 to 2 or 1.5 to 2.

[0354] 59. The reactor of any one of aspects 35 to 58, wherein the feedstock injection means comprises at least one injection opening and / or at least one nozzle, and the at least one injection opening and / or the at least one nozzle is arranged substantially perpendicular to a central longitudinal axis of the reactor and / or at an angle in the range of 70 to 90°, e.g., 75 to 89°, 80 to 88°, relative to the central longitudinal axis of the reactor.

[0355] 60. The reactor of any one of aspects 35 to 59, wherein the reactor further comprises a quench chamber downstream of the reaction chamber subsequent to the reaction chamber, the quench chamber preferably comprising means for reducing the temperature by injecting a quench medium into a flow path along the central longitudinal axis of the reactor or using a heat exchanger.

[0356] 61. 1. A carbon black produced according to any one of embodiments 1 to 34, preferably using a reactor as described in any one of embodiments 35 to 60.

[0357] 62. Use of a minimum molar percentage of plasma gas, plasma gas having a critical temperature below a temperature of the gas, and / or material having a critical temperature below a temperature of the gas (preferably plasma gas having a critical temperature below a temperature of the gas), preferably for a reactor as described in any one of embodiments 35 to 60, preferably utilizing a method according to any one of embodiments 1 to 34, to prevent the formation of droplets in a reactor (or condensation in the reactor) in carbon black production, where the plasma gas and the carbon black feedstock are mixed prior to subjecting the gases to the plasma zone, and the minimum molar percentage is based on the total molar amount of plasma gas including the carbon black feedstock, and is greater than or equal to x. dilutant Greater than x dilutant is calculated according to formula (V), formula (IX) and / or formula (XVII),

number

number

number

number

number

[0358] 62. In a reactor for producing carbon black having a flow path along a central longitudinal axis of the reactor, preferably as described in any one of embodiments 35 to 60, use of at least two injection means for carbon black feedstock, preferably according to any one of embodiments 1 to 34, to prevent the formation of droplets in the reactor (or condensation in the reactor), wherein the reactor comprises (A) a reaction chamber, (B) injection means for supplying the carbon black feedstock, and (C) means for generating a plasma in the reaction chamber, thereby forming a plasma zone, wherein (i) the injection means for supplying the carbon black feedstock are located upstream of the plasma zone, (ii) the injection means for supplying the carbon black feedstock are located in the plasma zone, but preferably after the region where the plasma is generated, and / or (iii) the injection means for supplying the carbon black feedstock are located downstream of the plasma zone, preferably immediately after the plasma zone.

[0359] 63. 63. The use according to embodiment 62, wherein the at least two injection means are (i) an injection means for supplying carbon black feedstock, located upstream of the plasma zone, and (ii) an injection means for supplying carbon black feedstock, located in the plasma zone, but preferably after the region where the plasma is generated. [Explanation of symbols]

[0360] 002 Reaction chamber 003 Microwave Plasma Generator 004 Plasma 005 Lining 090 Transverse axis 091 Lateral axis 100 Reactor 101 central longitudinal axis of reactor 102 Plasma gas 103 Carbon black raw materials 110 Tubular conduit 111 Raw material lance 113a, 113b Swivel elements 114a, 114b Swivel elements 150 Inflow funnel

Claims

1. A method for producing carbon black, comprising: (a) injecting a plasma gas into a carbon black reactor; (b) subjecting a plasma gas to the plasma zone to obtain a product mixture comprising carbon black; (c) quenching the product mixture; (d) separating the carbon black from the product mixture; wherein (i) the plasma gas comprises or consists of a carbon black raw material; (ii) the carbon black raw material is injected into the plasma gas upstream of the plasma zone; (iii) the carbon black raw material is injected into the plasma zone; and / or (iv) the carbon black raw material is injected into the plasma gas downstream of the plasma zone.

2. 10. The method of claim 1, wherein the plasma is generated in response to excitation of the plasma gas by microwave energy, the plasma is generated in response to excitation of the plasma gas by an electric arc, the plasma is generated in response to excitation of the plasma gas by a corona discharge, the plasma is generated in response to excitation of the plasma gas by a dielectric barrier discharge (DBD), and / or the plasma is generated in response to excitation of the plasma gas by radio frequency energy.

3. 3. The method of claim 1 or 2, wherein the plasma gas is preheated prior to subjecting the gas to the plasma zone.

4. The plasma gas is hydrogen and / or H ２ Contains O or hydrogen and / or H ２ 3. The method of claim 1 or 2, wherein the plasma gas is O and / or the plasma gas comprises or is a carbon black raw material.

5. 3. The method of claim 1 or 2, wherein the plasma gas and the carbon black feedstock are mixed in a molar ratio that does not cause the carbon black feedstock to form droplets in the carbon black reactor prior to subjecting the gases to the plasma zone.

6. 3. The method of claim 1 or 2, wherein the plasma gas containing the carbon black raw material is subjected to the following steps before subjecting the gas to the plasma zone: (i) when the final normal boiling point of the carbon black raw material is between 270 and 300 K and the temperature of the gas mixture is between 250 and 290 K, it contains between 1 mol % and 20 mol % of a material having a critical temperature below the temperature of the gas; (ii) when the final normal boiling point of the carbon black raw material is greater than 300 to 350 K and the temperature of the gas mixture is 270 to 290 K, it contains 30 to 95 mol % of a material having a critical temperature below the temperature of the gas; (iii) when the final normal boiling point of the carbon black raw material is greater than 350 to 400 K and the temperature of the gas mixture is 340 to 360 K, it contains 50 to 80 mol % of a material having a critical temperature below the temperature of the gas; (iv) when the final normal boiling point of the carbon black raw material is greater than 400 to 450 K and the temperature of the gas mixture is between 390 and 420 K, it contains 50 to 75 mol % of a material having a critical temperature below the temperature of the gas; (v) when the final normal boiling point of the carbon black raw material is greater than 450 to 500 K and the temperature of the gas mixture is 440 to 460 K, it contains 40 to 65 mol % of a material having a critical temperature below the temperature of the gas; (vi) when the final normal boiling point of the carbon black feedstock is greater than 500 to 550 K and the temperature of the gas mixture is 490 to 520 K, contains 20 to 65 mol % of a material having a critical temperature below the temperature of the gas; (vii) when the final normal boiling point of the carbon black feedstock is greater than 550 to 610 K and the temperature of the gas mixture is between 540 and 570 K, it contains 20 to 55 mol % of a material having a critical temperature below the temperature of the gas; or (viii) When the final normal boiling point of the carbon black feedstock is greater than 610 to 670 K and the temperature of the gas mixture is 590 to 630 K, the process comprises 30 to 65 mol % of a material having a critical temperature below the temperature of the gas.

7. The plasma gas and carbon black feedstock are mixed prior to subjecting the gases to the plasma zone, and the mole percent of the plasma gas, the mole percent of the plasma gas having a critical temperature below the temperature of the gas, and / or the mole percent of the material having a critical temperature below the temperature of the gas is greater than or equal to x, based on the total molar amount of the plasma gas including the carbon black feedstock. ｄｉｌｕｔａｎｔ Greater than x ｄｉｌｕｔａｎｔ The method according to claim 1 or 2, wherein is calculated according to formula (V), formula (IX) and / or formula (XVII): [Equation 1] In the formula, x ｄｉｌｕｔａｎｔ is the dilution factor, P [Pa] is the pressure of the plasma gas mixture, and P ０ [Pa] is atmospheric pressure, set to 101325 Pa, and Δ ｖａｐ H ｍ [J / mol] is the standard molar enthalpy of vaporization of the carbon black raw material, R [J / mol / K] is the universal gas constant, i.e., 8.314463 J / mol / K, T [K] is the system temperature or temperature of the plasma gas mixture, and T ｂ [K] is the standard value of the carbon black raw material (atmospheric pressure P ０ = 101325 Pa), [Equation 2] In the formula, x ｄｉｌｕｔａｎｔ is the dilution factor, P [Pa] is the pressure of the plasma gas mixture, i represents each compound in the carbon black feedstock, and Σ ｉ＝１ Ｎ is the sum of i=1 to N, where i is the compound index of the compound in the carbon black raw material, and x ｉ ｖａｐｏｕｒ is the mole percentage of each compound in the carbon black feedstock, and P ｉ ｓ [Pa] is the vapor pressure of each compound i in the carbon black raw material at the plasma gas temperature T [K], and P ｉ ｓ is calculated according to formula (X): [Equation 3] P ０ [Pa] is atmospheric pressure, set to 101325 Pa, and Δ ｖａｐ H ｍ，ｉ where [J / mol] is the standard molar enthalpy of vaporization of each compound in the carbon black feedstock, R [J / mol / K] is the universal gas constant, i.e., 8.314463 J / mol / K, T [K] is the system temperature or temperature of the plasma gas mixture, and T ｂ，ｉ [K] is the standard (atmospheric pressure P ０ = 101325 Pa), [Equation 4] In the formula, x ｄｉｌｕｔａｎｔ is the dilution factor, P [Pa] is the pressure of the plasma gas mixture, i represents each sample of carbon black raw material, and Σ ｉ＝１ １０ is the sum of i=1 to N, where i is the compound index of the carbon black raw material sample, and x ｐｓｅｕｄｏ，ｉ ｖａｐｏｕｒ is the mole percentage of each sample of carbon black raw material, and P ｐｓｅｕｄｏ，ｉ ｓ [Pa] is the vapor pressure of each sample i of the carbon black raw material at the plasma gas temperature T [K], and P ｐｓｅｕｄｏ，ｉ ｓ is calculated according to formula (XVIII): [Equation 5] P ０ [Pa] is atmospheric pressure, set to 101325 Pa, and Δ ｖａｐ H ｍ，ｉ [J / mol] is the standard molar enthalpy of vaporization of each sample of carbon black raw material, R [J / mol / K] is the universal gas constant, i.e., 8.314463 J / mol / K, T [K] is the system temperature or temperature of the plasma gas mixture, and T ｂ，ｉ [K] is the standard pressure (atmospheric pressure P ０ = 101,325 Pa).

8. 3. The method according to claim 1 or 2, wherein the reaction chamber is designed as a Laval nozzle, the plasma is generated at the constriction of the Laval nozzle, and / or the plasma gas is swirled before subjecting the gas to the plasma zone.

9. 1. A reactor for producing carbon black, the reactor having a flow path along a central longitudinal axis of the reactor, comprising: (A) a reaction chamber; (B) an injection means for supplying carbon black feedstock; (C) means for generating a plasma within the reaction chamber, thereby forming a plasma zone; wherein (i) the injection means for supplying the carbon black raw material is located upstream of the plasma zone, (ii) the injection means for supplying the carbon black raw material is located in the plasma zone, and / or (iii) the injection means for supplying the carbon black raw material is located downstream of the plasma zone.

10. 10. The reactor of claim 9, wherein the reaction chamber is designed as a Laval nozzle comprising a constriction in which the plasma is generated and / or the means for generating the plasma is an arc plasma generator, a microwave plasma generator, a radio frequency (RF) plasma generator, a corona discharge plasma generator or a dielectric barrier discharge (DBD) plasma generator.

11. 11. The reactor of claim 9 or 10, wherein the inner lining of the reaction chamber comprises aluminum oxide.

12. 11. The reactor of claim 9 or 10, wherein the reactor further comprises a swirling element capable of swirling the plasma gas, the swirling element being mounted upstream of the reaction chamber.

13. 3. Carbon black produced according to the method of claim 1 or 2.

14. 1. The use of a plasma gas, a plasma gas having a critical temperature below the temperature of the gas, and / or a minimum mole percentage of a material having a critical temperature below the temperature of the gas to prevent droplet formation in a reactor in carbon black production, wherein the plasma gas and the carbon black feedstock are mixed before subjecting the gas to a plasma zone, and the minimum mole percentage is greater than or equal to x, based on the total molar amount of plasma gas including the carbon black feedstock. ｄｉｌｕｔａｎｔ Greater than x ｄｉｌｕｔａｎｔ is calculated according to formula (V), formula (IX) and / or formula (XVII), [Equation 6] In the formula, x ｄｉｌｕｔａｎｔ is the dilution factor, P [Pa] is the pressure of the plasma gas mixture, and P ０ [Pa] is atmospheric pressure, set to 101325 Pa, and Δ ｖａｐ H ｍ [J / mol] is the standard molar enthalpy of vaporization of the carbon black raw material, R [J / mol / K] is the universal gas constant, i.e., 8.314463 J / mol / K, T [K] is the system temperature or temperature of the plasma gas mixture, and T ｂ [K] is the standard value of the carbon black raw material (atmospheric pressure P ０ = 101325 Pa), [Equation 7] In the formula, x ｄｉｌｕｔａｎｔ is the dilution factor, P [Pa] is the pressure of the plasma gas mixture, i represents each compound in the carbon black feedstock, and Σ ｉ＝１ Ｎ is the sum of i=1 to N, where i is the compound index of the compound in the carbon black raw material, and x ｉ ｖａｐｏｕｒ is the mole percentage of each compound in the carbon black feedstock, and P ｉ ｓ [Pa] is the vapor pressure of each compound i in the carbon black raw material at the plasma gas temperature T [K], and P ｉ ｓ is calculated according to formula (X): [Equation 8] P ０ [Pa] is atmospheric pressure, set to 101325 Pa, and Δ ｖａｐ H ｍ，ｉ where [J / mol] is the standard molar enthalpy of vaporization of each compound in the carbon black feedstock, R [J / mol / K] is the universal gas constant, i.e., 8.314463 J / mol / K, T [K] is the system temperature or temperature of the plasma gas mixture, and T ｂ，ｉ [K] is the standard (atmospheric pressure P ０ = 101325 Pa), [Equation 9] In the formula, x ｄｉｌｕｔａｎｔ is the dilution factor, P [Pa] is the pressure of the plasma gas mixture, i represents each sample of carbon black raw material, and Σ ｉ＝１ １０ is the sum of i=1 to N, where i is the compound index of the carbon black raw material sample, and x ｐｓｅｕｄｏ，ｉ ｖａｐｏｕｒ is the mole percentage of each sample of carbon black raw material, and P ｐｓｅｕｄｏ，ｉ ｓ [Pa] is the vapor pressure of each sample i of the carbon black raw material at the plasma gas temperature T [K], and P ｐｓｅｕｄｏ，ｉ ｓ is calculated according to formula (XVIII): [Equation 10] P ０ [Pa] is atmospheric pressure, set to 101325 Pa, and Δ ｖａｐ H ｍ，ｉ [J / mol] is the standard molar enthalpy of vaporization of each sample of carbon black raw material, R [J / mol / K] is the universal gas constant, i.e., 8.314463 J / mol / K, T [K] is the system temperature or temperature of the plasma gas mixture, and T ｂ，ｉ [K] is the standard pressure (atmospheric pressure P ０ = 101,325 Pa).

15. Use of at least two injection means for carbon black raw material in a reactor for producing carbon black having a flow path along a central longitudinal axis of the reactor to prevent droplet formation within the reactor, wherein the reactor comprises (A) a reaction chamber, (B) an injection means for supplying the carbon black raw material, and (C) a means for generating plasma in the reaction chamber, thereby forming a plasma zone, wherein (i) the injection means for supplying the carbon black raw material is located upstream of the plasma zone, (ii) the injection means for supplying the carbon black raw material is located in the plasma zone, and / or (iii) the injection means for supplying the carbon black raw material is located downstream of the plasma zone.

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