A method for producing carbon black from low-yield raw materials, and the product produced therefrom.

Abstract

The present invention relates to a method for producing carbon black using low-yield carbon black supply materials as defined and described herein. The present invention further relates to carbon black produced from one or more of these methods. [Solution] The method for producing carbon black according to the present invention includes introducing a heated gas stream into a carbon black reactor, mixing at least one first carbon black feed material with the heated gas stream to form a reaction stream, mixing at least one low-yield carbon black feed material downstream with the existing reaction stream to form carbon black, and recovering the carbon black in the reaction stream.

Description

[Technical Field]

[0001] The present invention relates to a method for producing carbon black produced from alternative carbon black production feedstocks, which often include gaseous and / or low-yield feedstocks. The present invention further relates to carbon black formed from alternative carbon black production feedstocks, which include gaseous and / or low-yield carbon black feedstocks.

[0002] Carbon black has been used to modify the mechanical, electrical, and optical properties of compositions. Carbon black and other fillers have been used as pigments, fillers, and / or reinforcing agents in the formulation and preparation of compositions used in rubber, plastic, paper, or textile applications. The properties of carbon black or other fillers are important factors in determining the various performance characteristics of these compositions. A key application of elastomer compositions is in tire manufacturing, where additional components are often added to impart specific properties to the final product or its components. Carbon black has been used to modify the functional properties, conductivity, rheology, surface properties, viscosity, appearance, and other properties of elastomer compositions and other types of compositions.

[0003] The most common conventional process for the industrial production of carbon black is the furnace process. In this method, a first liquid carbon-containing feedstock, such as decanted oil, is injected into a lean, high-temperature combustion gas stream or a gas stream during combustion. Part of the feedstock is thermally decomposed to produce carbon black and by-products (mainly hydrogen). The remainder is oxidized to produce CO, CO2, and H2O. Conventional or traditional feedstocks include decanted oil, slurry oil, coker oil, coal tar derivatives, or heavy liquid residues from the ethylene cracker process. These carbon black feedstocks are simultaneously heavy (specific gravity greater than 1.02), have an atomic H:C ratio of up to 1.23, are rich in aromatic compounds (Bureau of Mines Correlation Index (BMCI) greater than 100), and are liquid at room temperature and room pressure (e.g., 25°C at 1 atm). They are all generally derived from fossil fuels.

[0004] The furnace black process differs from the channel black and thermal black processes, which use natural gas as a feedstock. The channel black process utilizes thousands of small natural gas diffusion flames to produce small amounts of carbon black. The carbon black is collected on water-cooled metal channels or drums. The channel black process has an extremely low yield of approximately 0.05 kg C / kg feed and was consequently abandoned in the mid-20th century. The thermal black process produces certain types of ultra-low structure carbon black by passing a natural gas feed over preheated bricks. The natural gas is endothermally pyrolyzed into carbon black on the hot bricks. However, these bricks cool rapidly and must be periodically reheated by the combustion of by-products hydrogen and natural gas. The thermal black process produces only niche grades of carbon black with ultra-low structure and relatively low yields and cannot produce the majority of the surface area and structure of carbon black required for reinforcing tires, plastics, or industrial rubber compounds.

[0005] Using gaseous, renewable, recycled, and / or sustainable low-yield feedstocks in existing carbon black furnace processes is economically useful and environmentally beneficial. These feedstocks do not necessarily have to be fossil fuel-based. Examples include ethylene, which can be produced from ethane cracking or bioethanol. Another example is natural gas, which may be fossil-based or produced from landfills or organic matter decomposition. Further examples include vegetable oils; oils derived from the pyrolysis of recycled tires, plastics, municipal waste or biomass, or natural gas produced from landfills.

[0006] Unfortunately, these low-yield carbon black feedstocks generally result in lower yield, lower surface area, and / or lower structure in furnace processes compared to traditionally used furnace carbon black feedstocks. The performance of these feedstocks in furnace processes may be so poor that it may be impossible to produce the structure required for most ASTM grades using them. The maximum structure achievable at a given surface area for a feedstock helps define its grade capability.

[0007] Therefore, there is a need in the industry to provide a solution that allows the use of various amounts of low-yield carbon black forming feedstock in existing carbon black furnace processes (or enables such use), and furthermore, can produce carbon black comparable to that formed from conventional furnace carbon black feedstock (e.g., producing carbon black with acceptable yield and / or high surface area and / or high structure). Using existing furnace processes and these low-yield feedstocks, rather than developing, designing, and building new processes to use them, saves significant capital and development resources.

[0008] All patents and publications referred to throughout are hereby incorporated by reference in their entirety.

Summary of the Invention

[0009] A feature of the present invention is to provide a method for preparing or manufacturing carbon black from a feedstock that includes a low-yield carbon black feedstock (s).

[0010] A further feature of the present invention is to provide a method for preparing or manufacturing carbon black from a feedstock that includes a gaseous carbon black feedstock.

[0011] A further feature of the present invention is to provide carbon black manufactured from a feedstock that includes a low-yield carbon black feedstock.

[0012] Another feature of the present invention is to provide carbon black manufactured from a feedstock that includes a gaseous carbon black feedstock.

[0013] A further feature is to provide a method of using a carbon black feedstock, wherein at least a portion or more of the total amount of the feedstock is a low-yield carbon black feedstock.

[0014] A further feature is to provide a method for manufacturing carbon black from a low-yield carbon black feedstock such that the resulting carbon black has an acceptable (e.g., good) yield, an acceptable (e.g., high) surface area, and / or an acceptable structure (e.g., high structure).

[0015] To achieve these and other advantages, and in accordance with the objectives of the present invention, the present invention relates in part to a method for producing carbon black, as embodied and broadly described herein. The method comprises the steps of introducing a heated gas stream into a carbon black reactor (e.g., a furnace carbon black reactor) and mixing at least one first carbon black feedstock with the heated gas stream to form a reaction stream. The method further comprises the steps of mixing at least one low-yield carbon black feedstock downstream with the existing reaction stream to form carbon black. The method further comprises recovering the carbon black in the reaction stream. In the method, the at least one low-yield carbon black feedstock preferably comprises at least 10% by weight and 90% by weight or less (based on total weight) of the total feedstock. The first carbon black feedstock is preferably liquid at room temperature and room pressure (e.g., 25°C at 1 atm).

[0016] Furthermore, the present invention relates in part to a further method for producing carbon black. This method includes the steps of introducing a heated gas stream into a carbon black reactor (e.g., a furnace carbon black reactor), mixing a blend containing at least one first carbon black feedstock and at least one low-yield carbon black with the heated gas stream to form a reaction stream and to form carbon black. The method further includes recovering the carbon black in the reaction stream. In this method, the at least one low-yield carbon black feedstock preferably constitutes at least 10% by weight of the total feedstock and 90% by weight or less of the total feedstock (based on total weight). The first carbon black feedstock is preferably liquid at room temperature and room pressure (e.g., 25°C at 1 atm).

[0017] Furthermore, the present invention relates in part to carbon black(s) in which at least 10% by weight of the feedstock used to form the carbon black is at least one low-yield carbon black feedstock, and at least 10% by weight of the feedstock used to form the carbon black is at least one carbon black feedstock.

[0018] The present invention further relates to products and / or articles such as, but not limited to, elastomer composites formed from any one or more of the carbon blacks of the present invention.

[0019] It should be understood that both the foregoing general description and the following detailed description are merely exemplary and explanatory and do not limit the scope of the claimed invention.

[0020] The accompanying drawings, which are incorporated herein and constitute a part of this specification, illustrate various features of the present invention and, together with the detailed description, serve to explain the principles of the present invention.

Brief Description of the Drawings

[0021] [Figure 1] It is a graph showing the atomic H:C (hydrogen atom to carbon atom) ratio of a conventional carbon black feedstock compared to the low-yield feedstock partially used in the present invention.

[0022] [Figure 2] It is a graph showing the specific gravity of a conventional carbon black feedstock compared to the low-yield feedstock partially used in the present invention.

[0023] [Figure 3] It is a graph showing the BMCI value of a conventional feedstock compared to the low-yield feedstock partially used in the present invention.

[0024] [Figure 4A] It is a cross-sectional view of an example of a reactor suitable for preparing the carbon black of the present invention.

[0025] [Figure 4B] It is a cross-sectional view of another example of a reactor suitable for preparing the carbon black of the present invention.

[0026] [Figure 5] This is a cross-sectional view of a further example of a reactor suitable for preparing the carbon black of the present invention.

[0027] [Figure 6A] A schematic injector used in some of the comparative examples is shown in a side view. [Figure 6B] A schematic injector used in some of the comparative examples is shown in a side view.

[0028] [Figure 7] This graph plots the dimensionless yield and STSA (in m² / g units) for several examples and comparative examples of the present invention. The numbers refer to the example numbers in Tables 6 to 9. [Figure 8] This graph plots the dimensionless yield and STSA (in m² / g units) for several examples and comparative examples of the present invention. The numbers refer to the example numbers in Tables 6 to 9.

[0029] [Figure 9] This graph plots OAN and STSA (in m2 / g units) for several examples and comparative examples of the present invention. Numbers alone refer to the example numbers in Tables 6 to 9. The "N" number on the white diamond-shaped dots indicates data for the ASTM grade carbon black shown. For example, the dot "N330" shows the typical surface area and structure of N330 grade carbon black. [Figure 10] This graph plots OAN and STSA (in m2 / g units) for several examples and comparative examples of the present invention. Numbers alone refer to the example numbers in Tables 6 to 9. The "N" number on the white diamond-shaped dots indicates data for the ASTM grade carbon black shown. For example, the dot "N330" shows the typical surface area and structure of N330 grade carbon black.

[0030] [Figure 11]This graph plots OAN and STSA (in m2 / g units) for several examples and comparative examples of the present invention. Numbers shown only refer to the example numbers in Tables 10, 13, and 15. [Figure 12] This graph plots OAN and STSA (in m2 / g units) for several examples and comparative examples of the present invention. Numbers shown only refer to the example numbers in Tables 10, 13, and 15. [Figure 13] This graph plots OAN and STSA (in m2 / g units) for several examples and comparative examples of the present invention. Numbers shown only refer to the example numbers in Tables 10, 13, and 15.

[0031] [Figure 14] This graph plots the achievable yield for a given surface area for examples and comparative examples of the present invention. Numbers shown only refer to the example numbers in Table 15. [Modes for carrying out the invention]

[0032] The present invention relates to a method for producing carbon black using low-yield carbon black feedstocks as defined and described herein. The present invention further relates to carbon black produced from one or more of these methods. In the methods of the present invention, at least a portion of the total carbon black feedstocks used may be one or more low-yield carbon black feedstocks. The methods of the present invention allow for the use of small to large quantities of low-yield carbon black feedstocks without sacrificing the quality of the carbon black produced. Thus, the methods of the present invention utilize carbon black feedstocks that are more desirable to use for environmental and / or other reasons, and further produce carbon black comparable to carbon black produced using conventional carbon black feedstocks used in furnace carbon black processes.

[0033] The present invention relates to a method for producing carbon black, which comprises, consists of, or includes, introducing a heated gas stream into a carbon black reactor (e.g., a furnace carbon black reactor); mixing at least one first carbon black feedstock with the heated gas stream to form a reaction stream; mixing at least one low-yield carbon black feedstock downstream with the existing reaction stream to form carbon black; and recovering the carbon black in the reaction stream. Preferably, the at least one low-yield carbon black feedstock can constitute at least 10% by weight of the total feedstock, and more preferably at least 25% by weight of the total feedstock.

[0034] Another method of the present invention includes introducing a heated gas stream into a carbon black reactor (e.g., a furnace carbon black reactor), mixing a blend consisting of, comprising, or encompassing at least one first carbon black feedstock and at least one low-yield carbon black with the heated gas stream to form a reaction stream and form carbon black, and recovering the carbon black in the reaction stream. In this method, preferably, at least one low-yield carbon black feedstock may constitute at least 10% by weight of the total feedstock, and more preferably, at least 25% by weight of the total feedstock.

[0035] For the purposes of the present invention, the "low-yield carbon black supply material" is a carbon black supply material having at least one of the following characteristics. 1) Bureau of Mines Correlation Index (BMCI) less than 100 (providing an indicator of low aromatic content for liquid feed) (e.g., BMCI less than 99, less than 95, less than 90, less than 85, less than 80, less than 75, less than 70, e.g., BMCI between 50 and 99, or 60 and 99, or 70 and 99, or 50 and 95, or 50 and 90), and / or 2) A carbon-containing material that is a gas at room temperature (e.g., 25°C) and room pressure (1 atm), and / or 3) Atomic H:C ratios greater than 1.23 (for example, H:C ratios of 1.24 or higher, 1.25 or higher, 1.26 or higher, 1.27 or higher, 1.28 or higher, 1.29 or higher, 1.30 or higher, 1.35 or higher, 1.40 or higher, 1.45 or higher, 1.50 or higher, for example, 1.235~1.5, or 1.235~1.45, or 1.235~1.4, or 1.235~1.35, or 1.235~1.3, or 1.235~1.29, or 1.235~1.28, or 1.235~1.27, or 1.24~1.5, or 1.25~1.5, or 1.26~1.5, or 1.27~1.5, or 1.28~1.5, or 1.29~1.5, or 1.3~1.5), and / or 4) Specific gravity of up to 1.02 (for example, up to 1.015, up to 1.01, up to 1.005, up to 1.01, up to 1.00, up to 0.99, up to 0.95, for example, 0.80~1.019, or 0.80~1.015, or 0.80~1.01, or 0.80~1.005, or 0.80~1.00, or 0.80~0.95, or 0.80~0.9, or 0.80~1.015, or 0.90~1.01, or 0.90~1.005, or 1.005~1.015).

[0036] Low-yield carbon black feedstocks may only possess BMCI properties. Low-yield carbon black feedstocks may only possess atomic H:C properties. Low-yield carbon black feedstocks may only possess specific gravity properties. Low-yield carbon black feedstocks may only possess gaseous properties.

[0037] Low-yield carbon black feedstocks can possess BMCI properties and atomic H:C properties.

[0038] Low-yield carbon black raw materials can possess BMCI properties and specific gravity properties.

[0039] Low-yield carbon black feedstocks can possess BMCI properties and gaseous properties.

[0040] Low-yield carbon black supply raw materials may possess BMCI properties, atomic H:C properties, and specific gravity properties.

[0041] Low-yield carbon black feedstocks may possess BMCI properties, atomic H:C properties, and gaseous properties.

[0042] Low-yield carbon black supply raw materials may possess BMCI properties, atomic H:C properties, specific gravity properties, and gas properties.

[0043] Low-yield carbon black supply raw materials may have atomic H:C properties and specific gravity properties.

[0044] Low-yield carbon black supply raw materials may have atomic H:C properties and gaseous properties.

[0045] Low-yield carbon black supply raw materials may have atomic H:C properties, specific gravity properties, and gaseous properties.

[0046] Low-yield carbon black raw materials may have specific gravity and gas properties.

[0047] Low-yield carbon black feedstocks may be derived from sources considered to be sustainable, biological, and / or recycled. For example, a low-yield carbon black feedstock may be, or may contain, ethylene, which is a gas at room temperature and room pressure. Ethylene can be produced from bio-derived ethanol, for example, from maize fermentation or other plant material fermentation. Another example of a low-yield carbon black feedstock is natural gas.

[0048] For the purposes of the present invention, the low-yield carbon black feedstock may be feedstock not derived from fossil fuel-based gasoline production or coal cracking, or from cracking for the production of olefins. Therefore, the low-yield carbon black feedstock is a feedstock other than coal tar liquid, petroleum refined liquid, or ethylene cracker residue.

[0049] Other examples of raw materials for supplying low-yield liquid carbon black include, but are not limited to: tire pyrolysis oil, plastic pyrolysis oil, recycled oil, algal oil, plant-derived oil, oil derived from the pyrolysis of municipal solid waste, oil derived from the pyrolysis or decomposition of biomass (e.g., animal or plant) or agricultural waste, oil derived from the processing of pulp or paper manufacturing by-products, and / or other oils supplied primarily from biomaterials, or any combination thereof. Examples of low-yield feedstocks include, but are not limited to, vegetable oils or other plant-derived oils, bio-derived ethanol, oils obtained from plant or animal waxes or resins, animal fats, algal oils, oils obtained from the pyrolysis of sewage sludge or agricultural waste, by-product liquids from the processing of bio-based materials, liquids produced by the hydrothermal liquefaction of biomaterials, crude tall oil, tall oil rosin, tall oil pitch or tall oil fatty acids, oils obtained from recycled materials, oils obtained from the pyrolysis of low-quality tires, defective tires or tires at the end of their lifespan, oils obtained from the pyrolysis of discarded or recycled plastic or rubber products, oils obtained from the pyrolysis of municipal solid waste, or oils obtained from the pyrolysis of biomass, or any combination thereof. These liquid feedstocks have an atomic H:C ratio greater than 1.23, or a specific gravity of up to 1.02, or a BMCI value less than 100. The atomic H:C ratio can be measured according to ASTM D5291. The specific gravity can be measured according to ASTM D4052. BMCI can be measured according to Smith, H.M. (1940). Correlation Index To Aid In Interpreting Crude-Oil Analyses Technical Paper 610. Washington, DC, USD Department of the Interior, Bureau of Mines. Sulfur content can be measured according to IP-336 or ISO 8754 standards. Flash point can be measured according to ISO 2719. Specific examples of liquid low-yield carbon black feedstocks are shown in Table 1 below. [Table 1]

[0050] Figure 1 is a graph comparing the atomic H:C ratio of conventional high-yield carbon black feedstocks with that of tire pyrolysis oil (TPO), vegetable oil (Veg.Oil), and two types of gas-phase feedstocks (natural gas and ethylene) (Gas). For conventional feedstocks, the H:C ratio is plotted for a collection of approximately 1000 representative coal tar liquids, decant oils, and ECRs used as carbon black feedstocks for the furnace black process between 2016 and 2021. The range of H:C values ​​can be compared with three groups of low-yield carbon black feedstocks. It is clear that the H:C values ​​of conventional feedstocks are low, below 1.23 (dashed line in the figure). All of the low-yield carbon black feedstocks in Figure 1 have H:C values ​​greater than 1.23.

[0051] Figure 2 is a graph showing examples of the specific gravity of conventional high-yield feedstocks compared to tire pyrolysis oil (TPO) and vegetable oil (Veg.Oil). For conventional feedstocks, the specific gravity is plotted for a collection of approximately 1000 representative coal tar liquids, decant oils, and ECRs used as carbon black feedstocks for the furnace black process between 2016 and 2021. The specific gravity range is compared with two groups of low-yield carbon black feedstocks. It is clear that conventional feedstocks generally have a specific gravity greater than 1.02 (dashed line in the figure), while low-yield carbon black feedstocks have a specific gravity of 1.02 or less.

[0052] Figure 3 is a graph showing examples of BMCI numbers for conventional high-yield feedstocks compared to tire pyrolysis oil (TPO) and vegetable oil (Veg. Oil). For conventional carbon black feedstocks, the BMCI numbers are plotted for a collection of approximately 1000 representative coal tar liquids, decant oils, and ECRs used as feedstocks for the furnace black process between 2016 and 2021. Their BMCI values ​​are compared to two groups of low-yield feedstocks. Almost all conventional feedstocks have BMCI values ​​greater than 110, and all examples shown here have BMCI numbers greater than 100 (dashed line). In contrast, the TPO and vegetable oil groups have BMCI numbers less than 100.

[0053] Other examples of low-yield carbon black feedstocks include, but are not limited to, renewable feedstocks, bio-derived or bio-based feedstocks, and / or other by-products of the purification process, or any combination thereof.

[0054] Other examples of raw materials for low-yield carbon black supply include, but are not limited to, vegetable oils or other plant-derived oils (e.g., corn oil and / or corn distillate).

[0055] Other examples of low-yield carbon black supply sources include, but are not limited to, bio-derived ethanol (from corn fermentation, or fermentation products from other plants, vegetables, or fruits).

[0056] Other examples of raw materials for supplying low-yield carbon black include, but are not limited to, plant or animal waxes and resins, such as lanolin or lac.

[0057] Other examples of raw materials for supplying low-yield carbon black include, but are not limited to, oils obtained from animal fats.

[0058] Other examples of low-yield carbon black supply raw materials include, but are not limited to, algal oil.

[0059] Other examples of low-yield carbon black supply raw materials include, but are not limited to, oil obtained from the thermal decomposition of sewage sludge or agricultural waste.

[0060] Other examples of low-yield carbon black supply raw materials include, but are not limited to, liquid by-products from the processing of bio-based materials.

[0061] Other examples of low-yield carbon black supply materials include, but are not limited to, liquids produced by the hydrothermal liquefaction of biomaterials.

[0062] Other examples of raw materials for low-yield carbon black supply include, but are not limited to, crude tall oil, tall oil rosin, tall oil pitch, or tall oil fatty acids (e.g., from papermaking processes).

[0063] Other examples of low-yield carbon black supply sources include, but are not limited to, renewable supply sources, such as oil obtained from recycled materials.

[0064] Other examples of low-yield carbon black supply raw materials include, but are not limited to, oil obtained from the thermal decomposition of low-quality tires, substandard tires, or end-of-life tires.

[0065] Other examples of low-yield carbon black supply raw materials include, but are not limited to, oil obtained from the thermal decomposition of waste or recycled plastics.

[0066] Other examples of low-yield carbon black supply raw materials include, but are not limited to, oil obtained from the pyrolysis of municipal solid waste.

[0067] Other examples of raw materials for supplying low-yield carbon black include, but are not limited to, biomass, such as oils obtained from the thermal decomposition of animals or plants (e.g., vegetables) (bio-oils).

[0068] As described above, in the present invention, a portion (by weight) of all feedstocks used in the method of the present invention (introduced by stepwise or as a blend) is one or more low-yield carbon black feedstocks, and a portion is not a low-yield carbon black feedstock. Preferably, the amount of low-yield carbon black feedstocks (introduced by stepwise or as a blend) is at least 10% by weight, or at least 15% by weight, or at least 20% by weight, or at least 25% by weight, or at least 30% by weight, or at least 35% by weight, or at least 40% by weight, or at least 45% by weight, or at least 50% by weight, or at least 55% by weight, or at least 60% by weight, or at least 65% by weight, or at least 70% by weight, or at least 75% by weight, or at least 80% by weight, or at least 85% by weight, or at least 90% by weight, based on the total weight % of all feedstocks used, but less than 100% by weight, preferably less than 99% by weight or less than 95% by weight, for example, 10% to 95% by weight. , or 10% to 90% by weight, or 15% to 90% by weight, or 20% to 90% by weight, or 25% to 90% by weight, or 30% to 90% by weight, or 35% to 90% by weight, or 40% to 90% by weight, or 45% to 90% by weight, or 50% to 95% by weight, or 10% to 80% by weight, or 10% to 70% by weight, or 10% to 60% by weight, or These ranges from 10% to 50% by weight, or 10% to 40% by weight, or 10% to 30% by weight, or 60% to 95% by weight, or 65% to 95% by weight, or 70% to 95% by weight, or 75% to 95% by weight, or 60% to 95% by weight, or 60% to 90% by weight, or 60% to 85% by weight, or 60% to 80% by weight, or 60% to 75% by weight, etc.

[0069] For the purposes of the present invention, “first carbon black feedstock” or “high-yield carbon black feedstock” is a feedstock that is not a low-yield carbon black feedstock as defined herein. The first carbon black feedstock may be considered, or may be referred to as, a carbon black feedstock traditionally used in the furnace carbon black process (“traditional” carbon black feedstock). As will be further discussed herein, the first carbon black feedstock may optionally be a blend of feedstocks containing a small amount of low-yield carbon black feedstock.

[0070] The primary carbon black supply sources are typically from decant or slurry oil, coal tar or coal tar distillate, or families of ethylene or phenol cracker residues. Their distinct characteristics in typical furnace carbon black production are further described below.

[0071] The first carbon black supply raw material possesses all three of the following characteristics: 1) At least 100 (for example, at least 101, at least 102, at least 103, at least 104, at least 105, at least 110, at least 115, at least 120, at least 130, at least 140, at least 150, at least 160, at least 170, for example, 100-180, 101-180, 102 BMCI (for the following ranges): ~180, 103~180, 104~180, 105~180, 110~180, 115~180, 120~180, 130~180, 140~180, 150~180, 160~180, 100~175, 100~170, 100~165, 110~175, 115~175, 120~175, 125~170, 130~170) 2) Specific gravity greater than 1.02 (for example, greater than 1.025, greater than 1.03, greater than 1.035, greater than 1.04, greater than 1.05, for example, 1.021~1.3, or 1.025~1.3, or 1.03~1.3, or 1.05~1.3, or 1.07~1.25), 3) Atomic H:C ratio of up to 1.23 (e.g., up to 1.22, up to 1.21, up to 1.2, up to 1.15, up to 1.1, up to 1.05, up to 1, up to 0.9, up to 0.8, e.g., 1.225~0.7, 1.225~0.8, 1.225~0.9, 1.225~1, 1.225~1.1, 1.22~0.7, 1.21~0.7, 1.2~0.7). As an alternative, the first carbon black feedstock may also be a liquid at room temperature and room pressure (e.g., 25°C and 1 atm). Despite being a liquid, the first carbon black feedstock may be a pitch or similar material with extremely high viscosity and does not need to exhibit remarkable fluidity.

[0072] Examples of primary carbon black feedstocks are shown in Table 2 below and include coal tar, liquid distilled from coal tar, decant or slurry oil obtained from catalytic cracking, and residue oil from ethylene cracking. As shown in Table 2, these feedstocks have an H:C ratio of up to 1.23, a specific gravity greater than 1.02, and a BMCI value of at least 100.

[0073] [Table 2] [Table 3]

[0074] The first carbon black feedstock may also include fractions obtained from the refining or distillation of tire pyrolysis oil. Pyrolysis can be achieved by any method known to those skilled in the art. Examples include, but are not limited to, those found in U.S. Patent No. 8,350,105 and U.S. Patent Application Publication No. 2018,032,0082, both of which are incorporated herein by reference in their entirety. Distillation of the resulting oil can also be achieved by any method known to those skilled in the art. Examples include, but are not limited to, those found in U.S. Patent No. 9,920,262 and International Publication No. 2019,236,214, both of which are incorporated herein by reference. Distillation of tire pyrolysis oil can provide at least one fraction that can be used as a first carbon black feedstock, and at least one fraction that is a low-yield carbon black feedstock. In fact, distillation may yield a lighter fraction that can be used more economically in other unit processes of the carbon black production process, for example, as fuel for a dryer for carbon black, or as fuel for a heater for preheating either or both of the first or second carbon black feedstock, as disclosed in U.S. Patent Application Publication No. 20130039841, the contents of which are incorporated herein by reference. Thus, the integration of a distillation process with a carbon black reactor can enable both economic and environmental benefits from the recycling of carbon black-filled tires.

[0075] As an option, in the method of the present invention, based on the total amount of feedstock used (in weight %), the first carbon black feedstock is at least 10% by weight, or at least 15% by weight, or at least 20% by weight, or at least 25% by weight, or at least 30% by weight, or at least 35% by weight, or at least 40% by weight, or at least 45% by weight, or at least 50% by weight, or at least 55% by weight, or at least 60% by weight, or at least 65% by weight, or at least 70% by weight, or at least 75% by weight, or at least 80% by weight, or at least 85% by weight, or at least 90% by weight, but less than 100% by weight, preferably less than 99% by weight or less than 95% by weight, for example, 10% to 95% by weight, or 10% to 90% by weight. Weight %, or 15% to 90% by weight, or 20% to 90% by weight, or 25% to 90% by weight, or 30% to 90% by weight, or 35% to 90% by weight, or 40% to 90% by weight, or 45% to 90% by weight, or 50% to 95% by weight, or 10% to 80% by weight, or 10% to 70% by weight, or 10% to 60% by weight, or 10% to 50% by weight, or 10% to It can be used in amounts such as 40% by weight, or 10% to 30% by weight, or 60% to 95% by weight, or 65% to 95% by weight, or 70% to 95% by weight, or 75% to 95% by weight, or 60% to 95% by weight, or 60% to 90% by weight, or 60% to 85% by weight, or 60% to 80% by weight, or 60% to 75% by weight (introduced in a stepwise manner or as a blend). Based on the total amount of raw materials used (in weight %), other amounts of the first carbon black raw materials may be 49% by weight or less, 45% by weight or less, 40% by weight or less, 35% by weight or less, 30% by weight or less, 25% by weight or less, 20% by weight or less, 15% by weight or less, 10% by weight or less, 9% by weight or less, 8% by weight or less, 7% by weight or less, 6% by weight or less, for example, 5% to 49% by weight, or 5% to 45% by weight, or 10% to 40% by weight, or 10% to 35% by weight, or 10% to 30% by weight.

[0076] The first carbon black feedstock may be liquid under room temperature (e.g., 25°C) and atmospheric conditions (e.g., 1 atm). “Rich in aromatic species” means that the feedstock contains a large amount of aromatic compounds. For example, a large amount of aromatic compounds means that the total weight percentage of aromatic compounds present is at least 20% by weight, or that it has at least 100 BMCI, or both. The first carbon black feedstock can be heated to become a vapor, which may result in an aromatic species-rich vapor, or may actually be used as an aromatic species-rich vapor.

[0077] With respect to the steps of the method of the present invention, the method includes the step of forming a heated gas stream or introducing a heated gas stream into a carbon black reactor (e.g., a furnace carbon black reactor).

[0078] The “heated gas flow” may be a flow of high-temperature gas or high-temperature combustion gas. The heated gas flow can be generated by contacting a solid, liquid, and / or gaseous fuel with a suitable oxidizer flow, including but not limited to air, oxygen, or a mixture of air and oxygen. Alternatively, a preheated oxidizer flow may be passed through without the addition of a liquid or gaseous fuel. Examples of fuels suitable for use when contacting an oxidizer flow to generate high-temperature gas include any easily combustible gas, vapor, or liquid flow such as natural gas, hydrogen, carbon monoxide, methane, acetylene, alcohol, or kerosene. Generally, it is preferable to use fuels with a high carbon content, particularly hydrocarbons. The equivalent ratio (defined below) of the fuel-oxidizer mixture mixed to form the high-temperature gas can range from 10 (very fuel-rich) to about 0.1 (very fuel-lean), or the minimum value that still allows for the generation of high-temperature gas using a given combustor or oxidizer. As described above, the oxidizer flow can be preheated to facilitate the generation of high-temperature gas. Essentially, a heated gas stream is generated by igniting or burning a fuel and / or oxidizer. Temperatures such as approximately 1000°C to 3500°C can be achieved in a heated gas stream.

[0079] The carbon black reactor is preferably a furnace carbon black reactor. More preferably, the carbon black reactor is a version of a furnace reactor called a stepwise carbon black reactor (e.g., a multi-step carbon black reactor or multi-step reactor). "Stepwise" means that the feed material is introduced or injected at two or more axial positions along the long axis of the furnace.

[0080] For the purposes of this method and other methods described herein, multi-stage carbon black reactors such as those described in U.S. Patents 4,383,973, 7,829,057, 5,190,739, 5,877,251, 6,153,684, or 6,403,695 (all incorporated herein by reference in their entirety) may be used.

[0081] A general process for forming carbon black using a carbon black reactor such as a multi-stage reactor, and achieving a suitable high-temperature gas to form carbon black, is incorporated herein by reference and further described in the above-mentioned reference patent, which can be applied to the present invention with the modifications described herein.

[0082] Specific examples or embodiments of the present invention include cases where the low-yield carbon black feedstock includes, consists of, or is solely a pyrolysis oil, which is combined with at least one first carbon black feedstock as described herein. For the purposes of the present invention, the pyrolysis oil can be used as a blend with the first carbon black feedstock and / or introduced in stages (for example, by introducing the first carbon black feedstock first and then introducing the pyrolysis oil into the heated gas stream). Whether in a blending or staged manner, the pyrolysis oil can constitute 10% to 90% by weight of the total carbon black feedstock used in the process, and the first carbon black feedstock can constitute 10% to 90% by weight of the total carbon black feedstock used in the process. The various weight percentage ranges for the first carbon black feedstock and low-yield carbon black described above can be equally applied herein.

[0083] Specific examples or embodiments of the present invention also include cases where the low-yield carbon black feedstock includes, consists of, or is solely composed of ethylene and / or natural gas, and is combined with at least one first carbon black feedstock as described herein. For the purposes of the present invention, ethylene and / or natural gas can be used as a blend with the first carbon black feedstock and / or can be introduced in stages (for example, by introducing the first carbon black feedstock first and then introducing ethylene and / or natural gas into the heated gas stream). Whether in a blending or staged manner, ethylene and / or natural gas can constitute 10% to 90% by weight of the total carbon black feedstock used in the process, and the first carbon black feedstock constitutes 10% to 90% by weight of the total carbon black feedstock used in the process. A preferred option is when ethylene and / or natural gas constitute 30% to 90% by weight of the total carbon black feedstock used in the process, and the first carbon black feedstock constitutes 10% to 70% by weight of the total carbon black feedstock used in the process. The various weight percentage ranges for the first carbon black feedstock and low-yield carbon black described above can be equally applied here.

[0084] Specific examples or embodiments of the present invention include cases where the low-yield carbon black feedstock comprises, consists of, or consists solely of bio-based carbon black feedstocks (e.g., biogas, rapeseed oil, soybean oil, palm oil, sunflower oil, nut and / or olive oil and / or other vegetable oils and / or wood oils), and is combined with at least one first carbon black feedstock as described herein. For the purposes of the present invention, the bio-based (or bio-derived) carbon black feedstock can be used as a blend with the first carbon black feedstock and / or can be introduced stepwise (e.g., the first carbon black feedstock is introduced first, and then the bio-based carbon black feedstock is introduced into the heated gas stream). Whether in a blending or stepwise manner, the bio-based carbon black feedstock can constitute 10% to 90% by weight of the total carbon black feedstock used in the process, and the first carbon black feedstock constitutes 10% to 90% by weight of the total carbon black feedstock used in the process. A preferred option is when the bio-based carbon black feedstock constitutes 30% to 90% by weight of the total carbon black feedstock used in the process, and the first carbon black feedstock constitutes 10% to 70% by weight. The various weight percentage ranges for the first carbon black feedstock and low-yield carbon black described above can be equally applied here.

[0085] Figures 4A and 4B show cross-sectional views of a carbon black reactor that can be used (50 in Figure 4A and 80 in Figure 4B). In Figure 4A, the high-temperature combustion gas is produced in the combustion zone or combustion chamber 1 by contacting a fuel in the form of a liquid or gaseous fuel stream 9 with an oxidizer stream 5, for example, air, oxygen, or a mixture of air and oxygen (also known in the art as "oxygen-enriched air"). The fuel may be any readily combustible gas, vapor, or liquid stream, such as hydrocarbons (e.g., methane, natural gas, acetylene), hydrogen, alcohol, kerosene, or fuel mixtures. Often, the fuel of choice has a high carbon content.

[0086] Various gaseous or liquid fuels (e.g., hydrocarbons) can be used as combustion fuels. The equivalence ratio is the ratio of fuel to the amount of oxidizer stoichiometrically required to completely combust the fuel. Typical values ​​for the equivalence ratio in the combustion zone are in the range of 1.2 to 0.2. The oxidizer flow can be preheated to promote the generation of high-temperature combustion gases.

[0087] In this invention, the combustion process can consume the combustion fuel completely or almost completely. Oxygen, fuel selection, burner design, jet speed, mixing conditions and / or pattern, fuel-to-air ratio to air, oxygen-enriched air or pure oxygen, temperature, and / or other factors can be adjusted or optimized.

[0088] The high-temperature combustion gas flow flows downstream from zones 1 and 2 to zones 3 and 4. Carbon black feedstock is introduced at one or more suitable locations relative to other reactor components and feeds. Zone 2 of the combustion chamber may be the location where one or more carbon black feedstocks are introduced. In Figure 4A, carbon black feedstocks can be introduced into the reactor using injectors 10 and / or 6. Injector 10 can, for example, introduce or inject the first carbon black feedstock into the reactor. Alternatively, the first carbon black feedstock may also be introduced into the chamber using an axial pipe or lance (shown as pipe or lance 63 in Figure 4B). As a further alternative, the first carbon black feedstock may be injected or introduced simultaneously by multiple methods. Lances or any other injectors exposed to the reactor or combustion chamber may need to be cooled or protected from excessive heat in the combustion chamber by methods known in the art.

[0089] Further carbon black feedstock, such as low-yield carbon black feedstock, can be introduced into reactor zone 3 at injection point 7 by injector 6. In this invention, generally, at least a portion, if not all, of the first carbon black feedstock can be injected or introduced before the low-yield carbon black feedstock is introduced into the reactor. Preferably, the majority (more than 50%) of the first carbon black feedstock used in the reactor is introduced before any low-yield carbon black feedstock is introduced. Zones 3 and 4 are reaction zones, and zone 8 is a quenching zone. Q represents the length of zone 4 before quenching zone 8.

[0090] Carbon black feedstock can be injected into the combustion gas stream through one or more nozzles designed for optimal distribution of the feedstock into the combustion gas stream. Such nozzles may be single-fluid or dual-fluid. Dual-fluid nozzles can atomize the feedstock using, for example, steam, air, or nitrogen. Single-fluid nozzles may be pressure-atomized, or the feedstock may be injected directly into the gas stream. In the latter case, atomization is caused by the force of the gas stream.

[0091] The carbon black feedstock may be injected by an axial injection lance, or a central pipe may be used, and / or one or more radial lances may be arranged around the reactor in a plane perpendicular to the flow direction. The reactor may include several planes with radial lances along the flow direction. Spray nozzles or injection nozzles may be placed on the heads of the lances, thereby mixing the feedstock with the flow of heated gas.

[0092] Figure 4B shows a cross-section of another example of a carbon black reactor in a furnace process that can be used in the present invention. In this example, as in Figure 4A, the oxidizer stream 51 is mixed with the combustion fuel 52 in the combustion chamber 55.

[0093] The high-temperature combustion or partial combustion gas flow prepared in the chamber 55 flows in direction A toward the throat or constriction 64. The first carbon black feedstock is introduced into the furnace carbon black reactor 80 before the low-yield carbon black feedstock. The first carbon black feedstock can be introduced using any central pipe 63, or using a lance or injector or a set of lances 56, or via a lance or injector positioned in or near the throat 64 as indicated by 57. The first carbon black feedstock can be introduced at one of these locations, or at two of these locations simultaneously, or at all three locations simultaneously. The method and division of the first feedstock injection can be modified between these locations to alter product characteristics and process economics when two or more locations are used. The injectors and the combustion chamber itself (or a part thereof) can be cooled as needed by methods known in the art.

[0094] In Figure 4B, the length between an arbitrary central pipe injector 63 and the center of the tapered section 64 is shown as length 60. When this central pipe is used, this length is preferably 1 × 10 times the narrowest diameter of the first tapered section 64. When the central pipe is used simultaneously with an injector or lance array 57 for introducing the first carbon black feed material, the length 60 can be as described above or reduced to about 0. By adjusting this length, it is possible to balance the economics of the structure and process. The height or diameter 54 of the combustion chamber is shown, and this height may be greater than the height or diameter 64, and the height or diameter 64 may be at least 20%, at least 30%, at least 40%, or at least 50% smaller than the height or diameter 54.

[0095] Following the introduction of the first carbon black feedstock, the high-temperature gas stream mixed with the feedstock enters the first reaction chamber 58. The purpose of this chamber is to provide a residence time so that the pyrolysis reaction producing carbon black can complete its induction time and begin, and optionally to generate a seed particle population for later structure growth, as taught in U.S. Patent No. 7,829,057. The length of this chamber 66 can typically be 1 to 20 times the narrowest diameter of the first reduction section 64.

[0096] At the end of the first reaction chamber 58, a low-yield carbon black feedstock can be introduced. This may be introduced using an injector or injector array 59 located in or near the second reduction section 65. Alternatively, it may be introduced using a lance located substantially upstream of the reduction section 65 but within the chamber 58.

[0097] After the introduction of the low-yield carbon black feedstock, the mixture flows into a second reaction chamber 61. It is then quenched using a cooling spray of liquid or vapor 62, as is known in the art. The length from the injection point 59 of the low-yield carbon black feedstock to the quenching position 62 is shown as 67 in Figure 4B. This length is set to provide a residence time that controls specific product properties, as is known in the art of furnace processes.

[0098] In an alternative configuration, the first carbon black feedstock is introduced at positions 63 and / or 56, followed by the low-yield carbon black feedstock at positions 57 and / or 59, or simultaneously if both positions are used. This can provide a beneficial trade-off between carbon black structure capability and yield or process economics. In all of the above embodiments, at least a portion, preferably a large portion (more than 50%), of the first carbon black feedstock used, for example, all of the first carbon black feedstock, is introduced before and upstream of the low-yield carbon black feedstock.

[0099] In yet another example of the present invention, the first carbon black supply material may be a blend of a high-yield carbon black supply material that satisfies the above-described BMCI, specific gravity, and H:C parameters and a low-yield carbon black supply material, provided that the blend satisfies the above-described BMCI, specific gravity, and H:C parameters for the first carbon black supply material. The blend may contain more than 50% by mass of the high-yield carbon black supply material (for example, a high-yield carbon black supply material in the range of 50.5% to 99.5% by mass, such as 60% to 99% by mass). Similarly, the low-yield carbon black supply material may optionally be a blend of a high-yield carbon black supply material and a non-high-yield carbon black material that does not satisfy at least one of the BMCI, H:C, and specific gravity parameters required for the first carbon black supply material, provided that the blend also does not satisfy at least one of the BMCI, H:C, and specific gravity parameters required for the first carbon black supply material. Non-high yield carbon black feedstock may be present in amounts exceeding 50% by mass of the total feedstock in any blend (e.g., 50.5% by mass to 99.5% by mass of non-high yield carbon black feedstock, such as 60% to 99% by mass). In addition, the total amount of the first carbon black feedstock introduced into the reactor through the sum of all injection positions is less than 50% by mass based on the total amount of carbon black feedstock used at any point in the reactor. The total amount of low yield carbon black feedstock exceeds 50% by mass based on the total feedstock.

[0100] As an option, one method of the present invention includes the step of introducing at least one type of first carbon black feed material into a carbon black reactor together with a heating gas flow to form a reaction flow. The first carbon black feed material may be one type or a combination of two or more different first carbon black feed materials. If two or more types of feed materials are used as the first carbon black feed material, the multiple first carbon black feed materials may be blended together and injected as a single blended feed material through one or more locations, or each feed material may be injected separately into the combustion chamber at the same or different locations.

[0101] As an option, one method of the present invention includes the step of introducing at least one low-yield carbon black feedstock into the reaction flow. The low-yield carbon black feedstock may be one type or a combination of two or more different low-yield carbon black feedstocks. When two or more types of feedstocks are used as low-yield carbon black feedstocks, the multiple low-yield carbon black feedstocks may be blended together and injected as a single blended feedstock through one or more locations, or each feedstock may be injected separately into the combustion chamber at the same or different locations.

[0102] Generally, any of the carbon black feedstocks used in any of the methods of the present invention can be injected into the reactor in a single or multiple flow using an injector that penetrates the internal region of the high-temperature combustion gas flow. The injector can ensure a higher mixing ratio and shear between the high-temperature combustion gas and the carbon black feedstock(s). This ensures that the feedstock is thermally decomposed, preferably at a fast rate and / or high yield, to form the carbon black of the present invention.

[0103] Figure 5 shows specific examples of reactors that can be used to carry out the present invention and were used to produce the following Examples 1 to 13.

[0104] The first carbon black feedstock can be introduced at one or more locations in the reactor. This feedstock can be introduced, for example, by a central pipe or lance 73 located within the combustion chamber 74 having the largest diameter D-chamber 75 in the reactor 90, as shown in Figure 5. The central pipe can be positioned approximately on the centerline (axis center) of the reactor. The central pipe may have an injector head 77 or a spray head at its tip. The injector on the tip may have, for example, one or more holes (two, three, four, or more) around the tip (e.g., multiple holes roughly spaced evenly apart, as shown in Figure 6A where one of the multiple holes 610 is shown). This injection point can be achieved using the central pipe or by using other injection devices.

[0105] In one embodiment of the present invention, a low-yield carbon black feedstock can be introduced at one or more locations in the reactor. As shown, in this method of the present invention, one or more locations in the reactor are downstream(or more) of one or more locations where the first carbon black feedstock is injected or introduced. The introduction of the low-yield carbon black feedstock can be carried out, for example, using one or more injectors (e.g., metal pipes(or more) located on the wall of the reactor) that introduce the feedstock into the combustion chamber of the reactor, as shown in Figures 4A and 4B. The injectors may have an injector head or a spray head at their tip. The injectors on the tip may have, for example, one or more holes (two, three, four or more) around the tip (a plurality of holes that are roughly evenly spaced).

[0106] As an alternative, the introduction of low-yield carbon black feedstock into the reactor and reaction flow can be such that the feedstock is introduced perpendicular to the lateral flow of the reaction flow through the reactor, for example, as shown in Figures 4A and 4B. Perpendicular can be ±15 degrees from true vertical injection of the feedstock into the reaction flow.

[0107] As an alternative, the introduction of a low-yield carbon black feedstock into the reactor may be at a location with a narrower diameter than the diameter of the reactor where the first carbon black feedstock was previously introduced. This location can be considered a “throat” in some carbon black reactors. Figures 4A and 4B provide examples of this throat or throat region in a reactor. This narrower diameter can be at least 10%, at least 20%, at least 30%, or 10% to 40% smaller than the diameter of the reactor where the first carbon black feedstock was previously introduced. In Figure 5, this is D-chamber 75 versus D-throat 76.

[0108] As an option, the introduction of the low-yield carbon black feedstock into the reactor and reaction flow is at a distance D from the point where the first carbon black feedstock is introduced or injected into the reactor. A (In Figure 5, this distance is shown as L-pipe, 78) and this D A This distance is at least 1 or at least 2 times the narrowest diameter of the reactor's combustion chamber (or at least 2 times the diameter of the reactor into which the first carbon black feed material is introduced or injected). This distance may be at least 2.25 times, at least 2.5 times, at least 2.75 times, at least 3 times, at least 3.25 times, at least 3.5 times, at least 3.75 times, or at least 4 times the diameter of the reactor's combustion chamber (or at least 2.25 times, at least 2.5 times, at least 2.75 times, at least 3 times, at least 3.25 times, at least 3.5 times, at least 3.75 times, or at least 4 times the diameter of the reactor into which the first carbon black is introduced or injected).

[0109] Low-yield carbon black feedstock can be introduced at position 83 through one or more injectors.

[0110] After the feedstocks (first carbon black feedstock and low-yield carbon black feedstock) are mixed with the reaction flow, the method of the present invention generally includes a step of quenching the reaction. In Figure 5, this is the quenching spray 81. The reaction zone after the throat 76, indicated as 80, has a reactor with a maximum diameter D. L quenching indicates the length from where the low-yield carbon black feedstock is introduced to where quenching occurs.

[0111] The reaction is stopped in the quenching zone of the reactor (see zone 8 in Figure 4A). As shown in Figure 4A, quenching 8 is located downstream of reaction zone 4 and involves spraying a quenching fluid, such as water, into the flow of newly formed carbon black particles. Generally, quenching helps to cool the carbon black particles, lower the temperature of the gas flow, and reduce the reaction rate. Q is the distance from the starting point of reaction zone 4 to quenching point 8, and varies depending on the location of the quenching. Optionally, quenching may be stepwise or performed at several points in the reactor. Pressure spraying, gas atomization spraying, or other quenching techniques are also available. With regard to completely quenching the reaction for forming carbon black, any means known to those skilled in the art for quenching the reaction downstream of the introduction of the carbon black production feedstock may be used. For example, a quenching fluid, which may be water or other suitable fluid, can be injected to stop the chemical reaction.

[0112] After rapid cooling, the cooled gas and carbon black pass downstream to any conventional cooling means and a separation means from which the products are recovered. Separation of carbon black from the gas stream can be easily achieved by conventional means such as dust collectors, cyclone separators, bag filters, or other means known to those skilled in the art. After separating the carbon black from the gas stream, the carbon black can optionally be subjected to a pelletizing process.

[0113] In any of the methods of the present invention, as an option, the carbon black produced is not a carbon black having a core and a coating.

[0114] In any of the methods of the present invention, the carbon black is optionally formed completely in situ in the reactor.

[0115] As an option, one or more of the carbon black feedstocks or other components used in the method of the present invention may be preheated before being introduced into the reactor. For example, U.S. Patent No. 3,095,273 issued to Austin on June 25, 1963; U.S. Patent No. 3,288,696 issued to Orbach on November 29, 1966; U.S. Patent No. 3,984,528 issued to Cheng et al. on October 5, 1976; U.S. Patent No. 4,315,901 issued to Cheng et al. on February 16, 1982; U.S. Patent No. 4,765,964 issued to Gravley et al. on August 23, 1988. Appropriate preheating temperatures and / or preheating techniques can be used in the present invention, as described in U.S. Patent No. 5,997,837 issued to Lynum et al. on December 7, 999, U.S. Patent No. 7,097,822 issued to Godal et al. on August 29, 2006, U.S. Patent No. 8,871,173(B2) issued to Nester et al. on October 28, 2014, or Canadian Patent No. 682982 (all documents are incorporated herein by reference). Alternatively, low-yield carbon black feedstock may be preheated to a higher temperature than typical for high-yield feedstock. For example, low-yield carbon black feedstock can be heated to temperatures above 600°C, e.g., 600-800°C, even at ambient pressure. Since low-yield carbon black feedstock has a low concentration of asphaltene, heating to such high temperatures does not produce significant amounts of coke or other solid non-carbon black species. Alternatively, or in addition, one or more of the carbon black feedstocks may be mixed with the extender fluid before being introduced into the reactor, for example, as described in U.S. Patent No. 10,829,642 to Unrau (the entire contents of which are incorporated herein by reference).

[0116] Alternatively, this method may be carried out in the absence of at least one element from the periodic table's Group IA or Group IIA (or its ion), or at least one substance containing such element.

[0117] As an option, any of the methods of the present invention may include a step of introducing at least one substance that is or contains at least one Group IA or Group IIA element (or an ion thereof) of the periodic table. Preferably, the substance contains at least one alkali metal or alkaline earth metal. Examples include lithium, sodium, potassium, rubidium, cesium, francium, calcium, barium, strontium, or radium, or combinations thereof. Any mixture of one or more of these components may be present in the substance. The substance may be a solid, a solution, a dispersion, a gas, or any combination thereof. Two or more substances having the same or different Group IA or Group IIA metals may be used. If multiple substances are used, these substances may be added together, separately, sequentially, or at different reaction sites. For the purposes of the present invention, the substance may be the metal (or metal ion) itself, a compound containing one or more of these elements (including salts containing one or more of these elements), etc. Preferably, the substance may introduce the metal or metal ion into the reaction in progress to form the carbon black product. For the purposes of the present invention, preferably, the substance is introduced before complete quenching as described above. For example, the substance can be added at any point before complete quenching, including before the introduction of one or both of the carbon black production feedstocks, during the introduction of one or both of the carbon black production feedstocks, after the introduction of one or all of the carbon black production feedstocks, or after the introduction of all feedstocks but before complete quenching. Two or more points of introduction of the substance can be used. The amount of the group IA or group IIA metal-containing substance may be any amount, as long as a carbon black product can be formed. For example, the amount of substance can be added such that 200 ppm or more of group IA or group IIA elements are present in the carbon black product that is ultimately formed. Other amounts of group IA or group IIA elements present in the carbon black product that is formed include about 200 ppm to about 5000 ppm or more, other ranges of about 300 ppm to about 1000 ppm, or about 500 ppm to about 1000 ppm.These levels may relate to metal ion concentrations. As mentioned above, these amounts of Group IA or Group IIA elements present in the carbon black product formed may relate to one element or two or more Group IA or Group IIA elements, and thus represent the total amount of Group IA or Group IIA elements present in the carbon black product formed. Substances can be added in any form, including any conventional means. In other words, substances can be added in the same way that carbon black production feedstocks are introduced. Substances can be added as gases, liquids, solids, or any combination thereof. Substances can be added at one or more locations, and can be added in a single or multiple flow. Substances can be mixed with feedstocks, fuels, and / or oxidizers before or during their introduction.

[0118] With respect to carbon black formed by any of the methods of the present invention, the carbon black formed or manufactured may be any reinforced or unreinforced grade of carbon black. Examples of reinforced grades are N110, N121, N220, N231, N234, N299, N326, N330, N339, N347, N351, N358, and N375. Examples of semi-reinforced grades are N539, N550, N650, N660, N683, N762, N765, N774, N787, and / or N990.

[0119] Carbon black can also be furnace black.

[0120] Carbon black can be characterized by its specific surface area, structure, aggregate size, shape, and distribution, as well as / or surface chemical and physical properties. The properties of carbon black are determined analytically by tests known in the art. For example, nitrogen adsorption surface area, and statistical thickness surface area (STSA), another measure of surface area, are determined by nitrogen adsorption according to ASTM test procedure D6556. Iodine value can be measured using ASTM procedure D-1510. Carbon black "structure" refers to the size and complexity of carbon black aggregates formed by the fusion of primary carbon black particles. As used herein, carbon black structure can be measured as oil absorption (OAN) of unground carbon black, expressed as the number of milliliters of oil per 100 grams of carbon black, according to the procedure described in ASTM D-2414. Compressed sample oil absorption (COAN) measures the portion of the carbon black structure that does not readily change with the application of mechanical stress. COAN is measured according to ASTM D3493. The aggregate size distribution (ASD) is measured according to the ISO 15825 method using a disk centrifuge with a Brookhaven Instruments Model BI-DCP.

[0121] Carbon black materials with properties suitable for specific applications may be selected and defined by ASTM standards (see, for example, ASTM D1765 Standard Classification System for Carbon Blacks Used in Rubber Products), such as the N100, N200, N300, N500, N600, N700, N800, or N900 series of carbon blacks, such as N110, N121, N220, N231, N234, N299, N326, N330, N339, N347, N351, N358, N375, N539, N550, N650, N660, N683, N762, N765, N774, N787, or N990 carbon blacks, or other commercial grade standards.

[0122] Carbon black is 5 m 2 / g to 250 m 2 / g, 11 m 2 / g to 250 m 2 / g, 20 m 2 / g to 250 m 2 / g or more, for example, at least 70 m 2 / g, for example, 70 m 2 / g to 250 m 2 / g, or 80 m2 / g to 200 m 2 / g, or 90 m 2 / g to 200 m 2 / g, or 100 m 2 / g to 180 m 2 / g, 110 m 2 / g to 150 m 2 / g, 120 m 2 / g to 150 m 2 / g etc. and can have any STSA such as the range etc. As an option, the carbon black can have an iodine number (I2No) of about 5 to about 35 mg I2 / g carbon black (by ASTM D1510).

[0123] The carbon black particles disclosed herein can have a BET surface area of 5 m 2 / g to 300 m 2 / g, for example, 50 m 2 / g to 300 m 2 / g, for example, 100 m 2 / g to 300 m 2 / g measured by the Brunauer / Emmett / Teller (BET) technique according to the procedure of ASTM D6556. The BET surface area can be about 100 m 2 / g to about 200 m 2 / g or about 200 m 2 / g to about 300 m 2 / g and can be.

[0124] The oil absorption capacity (OAN) may be 40 mL / 100 g to 200 mL / 100 g, for example, 60 mL / 100 g to 200 mL / 100 g, for example, 80 mL / 100 g to 200 mL / 100 g, for example, 100 mL / 100 g to 200 mL / 100 g, or 120 mL / 100 g to 200 mL / 100 g, 140 mL / 100 g to 200 mL / 100 g, 160 mL / 100 g to 200 mL / 100 g, or for example, 40 mL / 100 g to 150 mL / 100 g, or 40 mL / 100 g to 150 mL / 100 g.

[0125] COAN may be within the range of approximately 40 mL / 100g to approximately 150 mL / 100g, for example, approximately 55 mL / 100g to approximately 150 mL / 100g, for example, approximately 80 mL / 100g to approximately 150 mL / 100g, or approximately 80 mL / 100g to approximately 120 mL / 100g.

[0126] Carbon black can be a carbon product containing silicon-containing species and / or metal-containing species, which can be achieved by including a further step of introducing such species together with or in addition to any or both of the carbon black production feedstocks. For the purposes of the present invention, carbon black may be a multiphase aggregate (also known as silicon-treated carbon black, e.g., ECOBLAK® material from Cabot Corporation) comprising at least one carbon phase and at least one metal-containing species phase or silicon-containing species phase.

[0127] As mentioned above, carbon black may be rubber black, in particular, reinforced grade carbon black or semi-reinforced grade carbon black.

[0128] As an option, the carbon black of the present invention may have functional or chemical groups (e.g., derived from ionic or nonionic small molecules or polymers) that are directly bonded (e.g., covalently) to the carbon surface. Examples of functional groups that can be directly bonded (e.g., covalently) to the surface of carbon black particles and methods for carrying out surface modification are described, for example, in U.S. Patent No. 5,554,739 issued to Belmont on September 10, 1996, and U.S. Patent No. 5,922,118 issued to Johnson et al. on July 13, 1999 (both incorporated herein by reference). As an example, surface-modified carbon black that can be used herein is obtained by treating carbon black with a diazonium salt formed by the reaction of either sulfanilic acid or para-aminobenzoic acid (PABA) with HCl and NaNO2. For example, surface modification by a sulfanilic or para-aminobenzoic acid process using a diazonium salt results in carbon black having an effective amount of hydrophilic moiety on the carbon coating.

[0129] Carbon black can be surface-modified in accordance with U.S. Patent No. 8,975,316 to Belmont et al., the contents of which are incorporated herein by reference in their entirety.

[0130] Other techniques that can be used to provide functional groups bonded to the surface of carbon black are described in U.S. Patent No. 7,300,964, issued to Niedermeier et al. on November 27, 2007.

[0131] Oxidized (modified) carbon black can be prepared in a manner similar to that used for carbon black, for example, as described in U.S. Patent No. 7,922,805 issued to Kowalski et al. on April 12, 2011, and U.S. Patent No. 6,471,763 issued to Karl on October 29, 2002 (these are incorporated herein by reference in their entirety). Oxidized carbon black is obtained by oxidizing with an oxidizing agent to introduce ionic groups and / or ionizable groups onto the surface. Such particles may have a higher degree of oxygen-containing groups on the surface. Examples of oxidizing agents include, but are not limited to, oxygen gas, ozone, peroxides such as hydrogen peroxide, persulfates including sodium persulfate and potassium persulfate, hypohalites such as sodium hypochlorite, oxidizing acids such as nitric acid, and transition metal-containing oxidizing agents such as permanganates, osmium tetroxide, chromium oxide, or cerium ammonium nitrate. Mixtures of oxidizing agents, in particular mixtures of gaseous oxidizing agents such as oxygen and ozone, can also be used. Other surface modification methods, such as chlorination and sulfonylation, can also be used to introduce ionic groups or ionizable groups. Carbon black may be surface modified by any method known to those skilled in the art. For example, carbon black may be heat-treated as described in U.S. Patent No. 1,0767028 (the entirety of which is incorporated herein by reference).

[0132] Carbon black can be used in a variety of applications, such as as a reinforcing agent in rubber products, for example, in tire components.

[0133] Carbon black can be incorporated into rubber articles used, for example, in tire treads, particularly treads; sub-treads; wire skims; sidewalls; cushioning rubber for retreaded tires; and other tire applications, such as those used in tires for passenger cars, light vehicles, trucks and buses, off-road ("OTR") tires, and aircraft tires.

[0134] In other applications, the particles can be used in industrial rubber articles such as engine mounts, hydro mounts, bridge bearings and seismic isolation devices, tank trucks or treads, mining belts, hoses, gaskets, seals, blades, gap fillers, bumpers, and vibration damping components.

[0135] Carbon black may be added in place of or in addition to a primary reinforcing agent for tire components and / or other industrial rubber end-uses. Carbon black may be mixed with natural and / or synthetic rubber in a suitable dry or wet mixing process based on an internal batch mixer, continuous mixer or roll mill.

[0136] Alternatively, carbon black may be mixed with rubber by a liquid masterbatch process. For example, a slurry containing the particles described herein may also be mixed with an elastomer latex in a vat and then coagulated by adding a coagulant such as an acid using the technique described in U.S. Patent No. 6,841,606.

[0137] Carbon black can be introduced in accordance with U.S. Patent No. 6,048,923, issued to Mabry et al. on April 11, 2000, which is incorporated herein by reference in its entirety. For example, a method for preparing an elastomer masterbatch may include simultaneously supplying a granular packing fluid and an elastomer latex fluid to the mixing zone of a solidification reactor. The solidification zone extends from the mixing zone and preferably has a gradually increasing cross-sectional area downstream from the inlet end to the discharge end. The elastomer latex may be natural or synthetic, and the granular packing includes, is essentially, or consists of the materials described above. The granular packing is preferably supplied to the mixing zone as a continuous high-speed jet of injection fluid, and the latex fluid is supplied at a low speed. The velocity, flow rate, and particle concentration of the particulate filler fluid are sufficient to cause high-shear mixing of the latex fluid and turbulent mixing of the mixture flow in at least the upstream portion of the solidification zone, thereby substantially completely solidifying the elastomer latex with the particulate filler before the discharge end. Substantially complete solidification can occur without the need for an acid or salt solidifying agent. Additional elastomers may be added to the material coming out of the discharge end of the solidification reactor, as disclosed in U.S. Patent No. 6,075,084, which is incorporated herein by reference in its entirety. The solidified material can then be fed to a dewatering extruder, as disclosed in U.S. Patent No. 6,929,783, which is incorporated herein by reference in its entirety. Other examples of preferred masterbatch processes are disclosed in U.S. Patent No. 6,929,783 to Chung et al., U.S. Patent Application Publication No. 2012 / 0264875(A1) to Berriot et al., U.S. Patent Application Publication No. 2003 / 0088006(A1) to Yanagisawa et al., and European Patent No. 1834985(B1) to Yamada et al.

[0138] Carbon black can be evaluated in appropriate rubber formulations using natural or synthetic rubber. The appropriate amount of carbon black to use can be determined by conventional experiments and calculations, taking into account factors such as the typical filling amount of standard ASTM furnace black in comparable manufacturing processes, parameters specific to the technology and / or equipment used, the presence or absence of other additives, and the desired properties of the final product.

[0139] The performance of carbon black as a reinforcing agent for rubber compounds can be evaluated, for example, by comparing the performance of a rubber composition utilizing the particles with the performance of a comparative rubber composition that is identical in all respects except for the use of a carbon black grade suitable for a given application. Alternatively, the values ​​obtained for compositions prepared according to the present invention can be compared with values ​​known in the art that are relevant to desired parameters in a given application.

[0140] Appropriate tests include the green rubber test, the curing test, and the cured rubber test. Among the appropriate green rubber tests, ASTM D4483 provides a test method for the ML1+4 Mooney viscosity test at 100°C. The scorch time is measured according to ASTM D4818.

[0141] The hardening curve was obtained using a rubber processing tester (RPA2000) at 0.5°, 100 cpm, and 150°C (NR) to 160°C (SBR) according to ASTM D5289.

[0142] The performance characteristics of the cured sample can be determined by a series of appropriate tests. Tensile strength, elongation at fracture, and stress at various strains (e.g., 100% and 300%) are all obtained by ASTM D412 Method A. Dynamic mechanical properties, including storage modulus, loss modulus, and tanδ, are obtained by strain sweep tests at 10 Hz, 60°C, and various strain amplitudes from 0.1% to 63%. Shore A hardness is measured according to ASTM D2240. Tear strength of die B cured rubber samples is measured according to ASTM D624.

[0143] The undispersed area is calculated by analyzing images obtained by reflection-mode optical microscopy of the cross-sectional area of ​​a cured rubber compound, according to various reported methods. Dispersion can also be expressed by the Z value (measured after reticularization according to the method described in the paper titled "New Reference value for the description of Filler Dispersion with the Dispergrader 1000NT" by S. Otto and Al in Kautschuk Gummi Kunststoffe, 58Jahrgang, NR7-8 / 2005). Standard ISO 11345 specifies a visual method for rapid comparative evaluation of the macrodispersion of carbon black and carbon black / silica in rubber.

[0144] Abrasion resistance is quantified as an index based on the friction loss of hardened rubber by Cabot Abrader (Lambourn type). Attractive abrasion resistance results can indicate favorable wear characteristics. Good hysteresis results can be associated with lower rolling resistance (and correspondingly higher fuel economy) for automotive tire applications, reduced heat buildup, tire durability, tread life and casing life, and fuel economy features for automobiles.

[0145] The iodine value (I2 No.) is determined according to ASTM test procedure D1510. The STSA (Statistical Thickness Surface Area) is determined based on ASTM test procedure D-5816 (measured by nitrogen adsorption). The OAN is determined based on ASTM D2414. The COAN is determined based on ASTM D3493 (e.g., D3493-20).

[0146] Unless otherwise specified, all material percentages expressed herein as percentages are weight percentages.

[0147] The present invention will be further illustrated by the following embodiments, which are intended to be essentially illustrative. [Examples]

[0148] Examples

[0149] For the purposes of the present invention and the examples presented herein, the following explanations of some terms are provided.

[0150] Equivalent ratio: Total equivalent ratio Φ for the partial oxidation process O This is the ratio obtained by dividing the molar flow rate of oxidizer required for the stoichiometric combustion of all input fuels and feedstocks by the actual molar flow rate of oxidizer. Therefore, Φ O If the ratio is greater than 1, the mixture is fuel-rich; if it is less than 1, the mixture is fuel-lean. The production of carbon black is preferably carried out by Φ O This is done when the fuel mixture is effectively rich, typically greater than 1.6.

[0151] Equivalent ratio Φ for combustion chambers that generate high-temperature combustion gases P This is defined by the amount of burner fuel and oxidizer supplied. Φ P This is typically a lean fuel mixture and takes values ​​between 0.33 and 0.9.

[0152] Equivalence ratio Φ I This is the equivalent ratio of the combustion chamber with any additional fuel or feed introduced through the central pipe shown in Figure 5, but excluding the feed introduced at the throat.

[0153] Yield: Yield Y is the mass of solid carbon obtained per unit of total mass of feedstock injected into the carbon black reactor, excluding natural gas used in the combustion chamber of Figure 5, and is in units of [kg C / kg feedstock]. Y is equal to the total mass flow rate of solid carbon produced in the reactor divided by the total mass flow rate of feedstock, which in the embodiments herein is measured by measuring the input flow rates of feedstock, burner fuel and all oxidizers, and the composition of the tail gas produced.

[0154] Carbon Content: The carbon content [C] is the mass-average carbon content of all carbon black feedstock introduced into the reactor, in units of [kg C / kg feedstock], and is equal to the total mass flow rate of carbon atoms entering the reactor through the feedstock divided by the total mass flow rate of the feedstock. This value is calculated according to the measured flow rates of the decant oil and ethylene feedstocks, as well as their measured elemental composition.

[0155] Dimensionless Yield: The dimensionless yield Y / [C] is obtained by dividing the above yield by the carbon content. This represents the proportion of the maximum possible yield obtained. For example, if Y / [C] = 0.5, this means that half of the feed carbon entering the reactor was converted into solid carbon. The remainder was lost as gaseous species.

[0156] Toluene extractable components, I2, STSA, OAN, and COAN

[0157] OAN and COAN are analyzed on the dry pellets according to the ASTM standards specified above. I2 valent and STSA are analyzed on the dry pellets according to the ASTM methods specified above.

[0158] Reactor configuration and operation

[0159] In the examples, decanted oil was used as the first carbon black supply material (Table 5), and ethylene gas was used as a low-yield carbon black supply material or a gaseous carbon black supply material.

[0160] As shown in Figure 5, the carbon black furnace method is used to mix natural gas and hot air in a combustion chamber to provide a high-temperature combustion gas flow. This combustion gas is fuel lean (oxidizer rich) and typically has an equivalent ratio Φ of 0.32 to 0.8. P It had the following features. The combustion chamber was lined with refractory material, and its inner diameter is shown in Table 3.

[0161] In some embodiments, a portion of the feed material was introduced using a central pipe 73, as shown in Figure 5. This pipe was positioned horizontally approximately on the centerline of the throat. The outer diameter of the pipe was 5.4 cm. When the feed material passing through the pipe was liquid decant oil, a circular full-surface spray or pressure spray with six equally spaced openings perpendicular to the long axis of the central pipe was used.

[0162] If the feedstock in the central pipe was ethylene, a low-yield carbon black feedstock, a gas injector 77, as shown in Figure 5, was used in the dimensions shown in the Table of Examples. This gas injector (Figure 6A, showing one of three holes 610 arranged radially at equal intervals around the tip) or Figure 6B (a coaxial gas injector with one hole 611) was attached to the end of the central pipe. If the feedstock was not injected in this manner, the central pipe was removed.

[0163] Next, the combustion gases from the chamber, along with the feedstock introduced through the central pipe (see Figure 5) if used, were directed to a narrower throat (76 in Figure 5) in the constriction section. In the throat, low-yield carbon black feedstock ethylene was injected using three gas injectors evenly spaced around the inner circumference of the throat. The injectors were straight metal tubes with an inner diameter of approximately 2 cm. They were positioned perpendicular to the direction of flow, as shown in Figure 5.

[0164] The throat was fitted into a reactor chamber lined with refractory material. The reactor chamber provided residence time for the feed material to complete the thermal decomposition into carbon black particles. Quenching was performed using a water spray at a distance L downstream of the injection surface shown in Figure 5, as is typical for the carbon black furnace method. Downstream of quenching, a filter was used to separate the carbon black particles from the tail gas stream. The carbon black on the filter was sampled for I2 absorption and toluene extractable components (S20). The carbon black was then pelletized and dried for STSA, OAN, and COAN measurements.

[0165] The filtered tail gas was sampled, its composition was measured under each condition, and the yield was determined. [Table 4]

[0166] The natural gas supplied to the combustion chamber in Figure 5 had the average composition measured as shown in Table 4 for each example. The components were measured by gas chromatography. [Table 5]

[0167] Table 4. Average composition of natural gas in experimental data

[0168] The ethylene used in the examples was 99% (by weight) purity ethylene, and no further analysis was performed.

[0169] The liquid decanted oil in these examples was the feedstock G listed in Table 2, and had the properties listed therein, as well as the properties shown in Table 5 below.

[0170] [Table 6]

[0171] result

[0172] Tables 6 to 9 show examples of carbon black production in the furnace process shown in Figure 5. Examples 1 to 5 and 11 to 13 show what happens when low-yield carbon black feedstock ethylene is used alone in the furnace, in the throat, in the central pipe, or in a stepwise manner, with some of the ethylene being injected in the central pipe followed by the remainder into the throat. Examples 6 to 10 and 14 to 18 demonstrate the advantages of the present invention compared to ethylene alone. In the present invention, a small amount of the total feedstock is a first carbon black feedstock injected through the central pipe, and the low-yield carbon black feedstock ethylene is injected into the throat.

[0173] As the results show, the use of low-yield carbon black feedstock alone resulted in a low yield for a given surface area (Figures 7 and 8), and its structural capability (as indicated by OAN or COAN) was too low to conform to most ASTM carbon black grades (Figures 9 and 10). While not bound by theory, these results may be at least in part due to the lower aromatic content of the low-yield carbon black feedstock compared to the first carbon black feedstock.

[0174] As at least partially demonstrated by the examples herein, the present invention offers several advantages. First, when the present invention is implemented, the dimensionless yield is significantly improved compared to when low-yield carbon black feedstock is used alone. Second, the ability to reach high structure is significantly increased by using the method of the present invention. Step-by-step processing using low-yield carbon black feedstock alone (Examples 4 and 5) does not achieve these gains. [Table 7] [Table 8] [Table 9] [Table 10]

[0175] Yield improvement

[0176] Figure 7 plots the dimensionless yields obtained from Examples 1-5 and 6-10 against surface area. The numbers on the data points refer to the example numbers in Tables 6-9. In Examples 1-5, ethylene is the only feedstock used. In Example 1, ethylene is injected only into the throat. In Examples 2 and 3, ethylene is injected using a coaxial injector and only through the central pipe (Figure 6B). In Examples 4 and 5, a portion of the ethylene feedstock is divided into stages through the central pipe (35% and 50% by mass), and the remainder is injected through the throat.

[0177] Examples 6 to 10 in the plot demonstrate the effects of the present invention compared to Examples 1 to 5. In Examples 6 to 10, a portion of the feedstock (25% by mass or 40% by mass) was decanted oil and injected through the central pipe as shown in Table 7. The dimensionless yields for all of these examples were significantly higher than those achieved with low-yield carbon black feedstock alone. In particular, compare Examples 1, 3, 4, and 5 in Figure 7 with Examples 6 and 7. The use of a relatively small amount (25%) of the first carbon black feedstock is 30-35 m 2 The yield obtained was significantly increased within a predetermined surface area range for STSA at / g.

[0178] Generally, the dimensionless yield decreases with increasing surface area in the carbon black furnace process, keeping other conditions constant. This is because a larger surface area requires higher temperatures, resulting in more oxidation and a lower yield to solid carbon. Therefore, the plot of dimensionless yield versus surface area shows a general downward trend with increasing surface area. This effect is highlighted by the ellipse in Figure 7. The classification of carbon blacks produced in this invention (Examples 6 to 10) lies on a trend line where their yields are much higher than those produced from ethylene alone (Examples 1 to 5).

[0179] Furthermore, it should be noted that the stage-by-stage processing of ethylene feedstock alone (Examples 4 and 5) does not significantly improve the yield obtained for a given surface area. The first carbon black feedstock or high aromatic content material appears to be required in the first stage to produce an effect.

[0180] Tables 8 and 9 are Φ P Examples of similar sets with higher values ​​are presented. The results are plotted in Figure 8. Examples 11 and 12 represent operations without embodiments of the present invention, as only ethylene was injected in either the throat or the central pipe. Examples 14 to 18 demonstrate the advantages of the present invention when a small amount of decanted oil is supplied through the central pipe. Again, as in Figure 7, the present invention significantly increases the yield achievable at a given surface area, and this rank is Φ P It is maintained independently of this. Here again, the classification of carbon black produced in the present invention (Examples 14 to 18) showed a trend of much higher yields than those produced from ethylene alone (Examples 11 and 12).

[0181] While not bound by any particular theory, it is assumed that the generation of seed particles from the first carbon black supply raw material introduced in the first stage is not significant, or at least not the sole factor producing the yield-increasing effect according to the present invention. Φ for Examples 6 and 7 IThe value was less than 1.6, suggesting that very few carbon black particles were produced from the oil in the central pipe. Nevertheless, a yield benefit was achieved. Therefore, the effect can be attributed, at least in part, to the aromatic content of the decant oil.

[0182] Improvement of structures with fixed surface area

[0183] A second advantage of the present invention is that it provides a substantial increase in the structure achievable at a given surface area, as shown in Figure 9. In this figure, the numbered data points refer to the example numbers in Tables 6 to 9. The "N" on the white diamond-shaped dots refers to the ASTM grade requirement for particle structure at a given surface area. All examples shown here do not use alkali metal additives and therefore represent the maximum structure achievable for the described operational configuration. As can be seen, low-yield carbon black feedstocks deficient in aromatics alone (Examples 1, 3, and 5) yielded carbon black grades with very low structure. With the use of the present invention, a much higher maximum structure was obtained (Examples 6 to 10).

[0184] It should also be noted that, as shown in Example 3, the segmentation of ethylene feedstock alone did little improvement to the structure achievable from low-yield carbon black feedstock. Instead, it appears that aromatic-rich, i.e., first carbon black feedstock, must be injected in the first stage.

[0185] Figure 9 shows a typical structure of a common, ASTM-listed carbon black grade (white diamond). This illustrates how the present invention can utilize supply materials that cannot produce common carbon black grades on their own, and helps to provide a method for producing these grades using such supply materials.

[0186] Similarly, Figure 10 shows the structure versus surface area from Tables 8 and 9. Again, the present invention demonstrates that the structure and surface area required for a typical carbon black grade can be obtained by injecting an aromatic-rich feedstock upstream of a low-yield carbon black feedstock, whereas this is not possible with the low-yield carbon black feedstock alone in a conventional carbon black furnace process.

[0187] Examples 19 to 26 in Tables 10A and 10B, and the figures based thereon, show examples where the low-yield carbon black feedstock was heavy tire pyrolysis oil, i.e., HTPO. HTPO is a recycled oil produced by the pyrolysis of used tire fragments. The oil is then distilled to produce a “heavy” or higher specific gravity oil fraction. The HTPO used in these examples had the properties shown in Table 11. The conventional feedstock for these examples was decanted oil, as similarly shown. [Table 11] [Table 12] [Table 13] * Estimates for corn oil were made based on its average boiling point of 375°C.

[0188] The reactor configurations for Examples 19 to 26 are shown in Figure 5. The key dimensions of this configuration are shown in Table 12. In these examples, a portion of the total feedstock (either decanted oil or a blend of decanted oil and HTPO) was injected into the central pipe 73 using the injectors shown in Table 12. The remainder of the total feedstock was injected into the throat 76 in Figure 5. The throat injector was a set of four small tubes, 0.7–1.5 mm in diameter, spaced equally around the throat and positioned perpendicular to the crossflow. The size of the throat injector was selected to allow sufficient penetration of the liquid feedstock into the throat's crossflow. [Table 14]

[0189] As shown in Figure 11, when pure HTPO was used, the structure measured by OAN was low at a single injection location (Examples 19 and 20). In Examples 21 and 22, a blend of 30% decanted oil and 70% HTPO was used in the throat, increasing the structure. In Examples 23 and 24, this same blend was used, except that 30% of the total feed was injected in the central pipe and the remainder in the throat. In Examples 25 and 26, decanted oil was injected in the central pipe as pure feed, while HTPO was injected in the throat as pure feed, so that decanted oil constituted 30% of the total feed injected and HTPO constituted 70%. This method, in which the first carbon black feed was conventional feed and the low-yield feed was injected downstream, produced the greatest structure capacity.

[0190] Examples 27 and 28 in Table 13 show examples in which the configuration shown in Figure 4B was used. Table 14 shows the dimensions of the reactors used in these examples. Figure 12 plots these examples together with Examples 21 and 22. [Table 15] [Table 16]

[0191] All examples in Figure 12 used an overall feedstock mixture of 30% decant oil and 70% HTPO. When this mixture was injected into a single throat having the configuration of Figure 5, a relatively low structure was obtained (Examples 21 and 22). This low structure was partly a result of relatively high alkali additives compared to Examples 27 and 28, but Examples 21 and 22 have the lowest structure even when no alkali is used. When the same mixture was injected into two throat positions, a higher structure was obtained (Example 28). However, when all of the first feedstock, i.e., the conventional feedstock, was injected into the first throat, and only the low-yield feedstock was used in the second throat, a higher structure was achieved for a given surface area (Example 27). The dotted lines on the data points are for reference only, and their slopes correspond to the slope between Example 22 and Example 21.

[0192] Examples 29 to 33 in Table 15 show examples where the low-yield feedstock was vegetable oil, in this case distilled corn oil. Table 11 shows the properties of the vegetable oil used in the experiments. The reactor configurations for these examples are shown in Figure 4B with the dimensions shown in Table 12. [Table 17]

[0193] Figure 13 shows the capabilities of exemplary embodiments to improve the structural capacity of weak feedstocks. All of these examples used 30% decanted oil and 70% distilled corn oil as carbon black feedstocks. In Examples 29 and 30, these two feedstocks were blended directly and injected into a single throat of the reactor. This resulted in a low structure with an OAN of less than 90 mL / 100 g. In Example 31, two throats were used, and although the structure was slightly improved when the feedstocks were blended directly, it was still low.

[0194] However, in exemplary embodiments where all the decant oil enters only the first throat, the structure was significantly increased, as shown in Examples 32 and 33. To do this, a blend of 50% decant oil and 50% corn oil was injected into the first throat, and 100% corn oil was injected into the second throat. The overall feedstock usage in these embodiments was the same as in Examples 29–33, with 30% of the total feedstock used being decant oil and 70% being distilled corn oil.

[0195] The use of the embodiments provided herein also improved the yield achievable at a given surface area, as shown in Figure 14. Direct blending of 30% decant oil and 70% corn oil into a single throat resulted in low yields (Examples 29 and 30), while the use of a dual throat only slightly improved this (Example 31). However, when all decant oil was injected into only the first throat (50% decant oil and 50% corn oil in the first throat, and 100% corn oil in the second throat), the dimensionless yield improved significantly (Examples 32 and 33). The dotted line in Figure 14 represents the slope of yield against surface area observed in Examples 29 and 30. This type of negative slope is typical of the furnace carbon black method.

[0196] The present invention includes the following aspects / embodiments / features in any order and / or any combination. 1. A method for producing carbon black, Introducing a heated gas stream into the furnace carbon black reactor, Mix at least one first carbon black feed material, constituting at least 10% by weight of the total feed material, with the heated gas flow to form a reaction flow. The process involves mixing at least one low-yield carbon black feed material, constituting at least 10% by weight of the total feed material, downstream with the existing reaction stream to form carbon black. To recover carbon black from the reaction stream, The first carbon black supply raw material is liquid at room temperature and room pressure and has the following characteristics: - Bureau of Mines Correlation Index (BMCI) of 100 or higher, - Atomic H:C ratio of 1.23 or less, -Specific gravity over 1.02, The raw materials for low-yield carbon black supply have the following characteristics: Bureau of Mines Correlation Index (BMCI) less than 100, or Atomic H:C ratio greater than 1.23, or Specific gravity 1.02 or less, Having at least one of the following, A method for determining whether something is a gas at room temperature and room pressure. 2. Low-yield carbon black supply raw materials are as follows: a) The Bureau of Mines Correlation Index (BMCI) is less than 95, or b) The above gas is present at room temperature and room pressure, or c) The above atomic H:C ratio is greater than 1.3, or d) The specific gravity is 1.0 or less. The method according to any of the above or below embodiments / features / appearances, which is at least one of the above. 3. The method according to any of the above or below embodiments / features / appearances, wherein the low-yield carbon black supply raw material is ethylene. 4. The method according to any of the above or below embodiments / features / appearances, wherein the low-yield carbon black supply raw material is natural gas. 5. A low-yield carbon black supply raw material having the above specific gravity of less than 1.02, according to any of the above or below embodiments / features / appearances. 6. The method according to any of the above or below embodiments / features / appearances, wherein the low-yield carbon black supply raw material is tire pyrolysis oil, or oil obtained from the distillation or fractional distillation of tire pyrolysis oil. 7. The method according to any of the above or below embodiments / features / appearances, wherein the low-yield carbon black feedstock is a feedstock other than coal tar liquid, petroleum refined liquid, or ethylene cracker residue or phenol cracker residue. 8. The method according to any embodiment / feature / approach described above or below, wherein the low-yield carbon black feedstock is plastic pyrolysis oil, high H:C:decant oil, renewable feedstock, bio-derived feedstock, or other by-products of the refining process, or any combination thereof. 9. The above bio-derived raw materials include at least one of the following: vegetable oil or other plant-derived oils, bio-derived ethanol, oils obtained from plant or animal waxes or resins, animal fats, algal oil, oils obtained from the thermal decomposition of sewage sludge or agricultural waste, by-product liquids from the processing of bio-derived materials, liquids produced by the hydrothermal liquefaction of biomaterials, crude tall oil, tall oil rosin, tall oil pitch or tall oil fatty acids, oils obtained from recycled materials, oils obtained from the thermal decomposition of low-quality tires, defective tires or tires at the end of their lifespan, oils obtained from the thermal decomposition of discarded or recycled plastic or rubber products, oils obtained from the thermal decomposition of municipal solid waste, or oils obtained from the thermal decomposition of biomass, or any combination thereof, as described in any of the above or below embodiments / features / appearances / methods. 10. The method according to any of the above or below embodiments / features / appearances, wherein the low-yield carbon black feedstock is in the range of 10 to 90% by weight of the total feedstock introduced in the above method. 11. The method according to any of the above or below embodiments / features / appearances, wherein the low-yield carbon black feedstock is in the range of 25 to 90% by weight of the total feedstock introduced in the above method. 12. The furnace carbon black reactor comprises a combustion chamber, a throat downstream of the combustion chamber, a reaction chamber downstream of the throat, and a quenching zone downstream of the reaction chamber, wherein a first carbon black feedstock is injected into the combustion chamber of the furnace carbon black reactor, and a low yield carbon black feedstock is injected into the throat, according to any of the above or below embodiments / features / appearances. 13. The method according to any of the above or below embodiments / features / appearances, wherein the combustion chamber has a certain diameter, and the low-yield carbon black feed material is injected at a distance of at least twice the diameter of the combustion chamber downstream from the location where the first carbon black feed material is injected. 14. The method according to any of the above or below embodiments / features / appearances, wherein the above-mentioned first carbon black feed material is introduced into the furnace carbon black reactor at at least two separate locations, one of which is downstream of the other. 15. The method according to any of the above or below embodiments / features / appearances, wherein the above-mentioned at least one low-yield carbon black feedstock is introduced into the furnace carbon black reactor at at least two separate locations, one of which is downstream of the other. 16. The method according to any of the above or below embodiments / features / appearances, wherein the above-mentioned first carbon black feedstock is a blend comprising less than 50% by weight of low-yield carbon black feedstock based on the total weight of the above-mentioned first carbon black feedstock. 17. The method according to any of the above or below embodiments / features / appearances, wherein the above-mentioned first carbon black supply material comprises 95% to 100% by weight of the above-mentioned first carbon black supply material based on the total weight of the above-mentioned first carbon black supply material. 18. The method according to any of the above or below embodiments / features / appearances, wherein the above-mentioned at least one low-yield carbon black supplying material comprises 95% to 100% by weight of the above-mentioned low-yield carbon black supplying material based on the total weight of the above-mentioned first carbon black supplying material. 19. The method according to any of the above or below embodiments / features / appearances, wherein the above-mentioned at least one low-yield carbon black supplying material is a blend comprising less than 50% by weight of a first carbon black supplying material based on the total weight of the above low-yield carbon black supplying materials. 20. The method according to any of the above or below embodiments / features / appearances, wherein the above low yield carbon black supply raw material has the above BMCI of less than 100. 21. The method according to any of the above or below embodiments / features / appearances, wherein the above low-yield carbon black supply raw material has the above atomic H:C ratio greater than 1.23. 22. The method according to any of the above or below embodiments / features / appearances, wherein the above low-yield carbon black supply material is the above gas at room temperature and room pressure. 23. The method according to any of the above or below embodiments / features / appearances, wherein the recovered carbon black is N110, N121, N220, N231, N234, N299, N326, N330, N339, N347, N351, N358, N375, N539, N550, N650, N660, N683, N762, N765, N774, N787, or N990 grade carbon black. 24. The method according to any of the above or below embodiments / features / appearances, wherein at least one low-yield carbon black feedstock is a pyrolysis oil present in an amount of 10% to 90% by weight based on the total feedstock, and at least one first carbon black feedstock is present in an amount of 10% to 90% by weight based on the total feedstock. 25. The method according to any of the above or below embodiments / features / appearances, wherein at least one low-yield carbon black feedstock is ethylene, natural gas, or both, present in an amount of 30% to 90% by weight based on the total feedstock, and at least one first carbon black feedstock is present in an amount of 10% to 70% by weight based on the total feedstock. 26. The method according to any of the above or below embodiments / features / appearances, wherein at least one low-yield carbon black feedstock is a bio-based feedstock present in an amount of 10% to 90% by weight based on the total feedstocks, and at least one first carbon black feedstock is present in an amount of 10% to 90% by weight based on the total feedstocks. 27. A method for producing carbon black, Introducing a heated gas stream into the furnace carbon black reactor, Mix at least one first carbon black feed material, constituting at least 10% by weight of the total feed material, with the heated gas flow to form a reaction flow. Mix at least one low-yield carbon black feed material, constituting at least 10% by weight of the total feed material, downstream with the existing reaction stream to form carbon black. To recover carbon black from the reaction stream, The first carbon black supply raw material is liquid at room temperature and room pressure and has the following characteristics: - Bureau of Mines Correlation Index (BMCI) of 100 or higher, - Atomic H:C ratio of 1.23 or less, -Specific gravity over 1.02, The raw materials for low-yield carbon black supply have the following characteristics: Bureau of Mines Correlation Index (BMCI) less than 100, or Atomic H:C ratio greater than 1.23, or Specific gravity 1.02 or less, Having at least one of the following, It is a gas at room temperature and room pressure. A method comprising: at least one low-yield carbon black feedstock being pyrolysis oil present in an amount of 10% to 90% by weight based on the total feedstocks; and at least one first carbon black feedstock being present in an amount of 10% to 90% by weight based on the total feedstocks. 28. A method for producing carbon black, Introducing a heated gas stream into the furnace carbon black reactor, Mix at least one first carbon black feed material, constituting at least 10% by weight of the total feed material, with the heated gas flow to form a reaction flow. The process involves mixing at least one low-yield carbon black feed material, constituting at least 10% by weight of the total feed material, downstream with the existing reaction stream to form carbon black. To recover carbon black from the reaction stream, The first carbon black supply raw material is liquid at room temperature and room pressure and has the following characteristics: - Bureau of Mines Correlation Index (BMCI) of 100 or higher, - Atomic H:C ratio of 1.23 or less, -Specific gravity over 1.02, The raw materials for low-yield carbon black supply have the following characteristics: Bureau of Mines Correlation Index (BMCI) less than 100, or Atomic H:C ratio greater than 1.23, or Specific gravity 1.02 or less, Having at least one of the following, It is a gas at room temperature and room pressure. A method comprising: at least one low-yield carbon black feedstock being ethylene, natural gas, or both, present in an amount of 30% to 90% by weight based on the total feedstocks; and at least one first carbon black feedstock being present in an amount of 10% to 70% by weight based on the total feedstocks. 29. A method for producing carbon black, Introducing a heated gas stream into the furnace carbon black reactor, Mix at least one first carbon black feed material, constituting at least 10% by weight of the total feed material, with the heated gas flow to form a reaction flow. Mix at least one low-yield carbon black feed material, constituting at least 10% by weight of the total feed material, downstream with the existing reaction stream to form carbon black. To recover carbon black from the reaction stream, The first carbon black supply raw material is liquid at room temperature and room pressure and has the following characteristics: - Bureau of Mines Correlation Index (BMCI) of 100 or higher, - Atomic H:C ratio of 1.23 or less, -Specific gravity over 1.02, The raw materials for low-yield carbon black supply have the following characteristics: Bureau of Mines Correlation Index (BMCI) less than 100, or Atomic H:C ratio greater than 1.23, or Specific gravity 1.02 or less, Having at least one of the following, It is a gas at room temperature and room pressure. A method comprising: at least one low-yield carbon black supplying material being a bio-based supplying material present in an amount of 10% to 90% by weight based on the total supplying materials; and at least one first carbon black supplying material present in an amount of 10% to 90% by weight based on the total supplying materials. 30. A method for producing carbon black, Introducing a heated gas stream into the furnace carbon black reactor, A blend comprising at least one first carbon black feedstock constituting at least 10% by weight of the total feedstock and at least one low-yield carbon black feedstock constituting at least 10% by weight of the total feedstock is mixed with the heated gas stream to form a reaction stream and to form carbon black. To recover carbon black from the reaction stream, The first carbon black supply raw material is liquid at room temperature and room pressure and has the following characteristics: - Bureau of Mines Correlation Index (BMCI) of 100 or higher, - Atomic H:C ratio of 1.23 or less, -Specific gravity over 1.02, The raw materials for low-yield carbon black supply have the following characteristics: Bureau of Mines Correlation Index (BMCI) less than 100, or Atomic H:C ratio greater than 1.23, or Specific gravity 1.02 or less, Having at least one of the following, It is a gas at room temperature and room pressure. A method comprising: at least one low-yield carbon black feedstock being pyrolysis oil present in an amount of 10% to 90% by weight based on the total feedstocks; and at least one first carbon black feedstock being present in an amount of 10% to 90% by weight based on the total feedstocks. 31. Carbon black manufactured by any method of any of the above or below embodiments / features / aspects.

[0197] The present invention may include any combination of the various features or embodiments described above and / or below in any sentence and / or paragraph of this specification. Any combination of the features disclosed herein is deemed to be part of the invention and is not intended to limit the range of combinatable features.

[0198] The applicants hereby specifically incorporate into this disclosure the entire contents of all cited references. Furthermore, where a quantity, concentration, or other value or parameter is given as a range, a preferred range, or a list of preferred upper and lower limits, this should be understood to specifically disclose all ranges formed from any pair of any upper or preferred value and any lower or preferred value of any range, regardless of whether the range is disclosed separately. Where a range of numerical values ​​is described herein, unless otherwise stated, the range is intended to include its endpoints, as well as all integers and fractions within that range. The scope of the present invention is not intended to be limited to any specific values ​​enumerated when defining a range.

[0199] Other embodiments of the present invention will be apparent to those skilled in the art from the discussion herein and the practice of the present invention disclosed herein. This specification and the examples, together with the true scope and spirit of the present invention as set forth by the following claims and equivalents, are intended to be illustrative only.

Claims

1. A method for producing carbon black, Introducing a heated gas stream into the furnace carbon black reactor, Mix at least one first carbon black supply material, constituting at least 10% by weight of the total supply material, with the heated gas flow to form a reaction flow, The carbon black is formed by mixing at least one low-yield carbon black supply material, which constitutes at least 10% by weight of the total supply material, with the existing reaction stream downstream. To recover the carbon black in the reaction stream, The first carbon black supply material is liquid at room temperature and room pressure and has the following characteristics: - Bureau of Mines Correlation Index (BMCI) 100 or higher, - Atomic H:C ratio of 1.23 or less, -Specific gravity over 1.02, The low-yield carbon black supply raw material has the following characteristics: Bureau of Mines Correlation Index (BMCI) less than 100, or Atomic H:C ratio greater than 1.23, or Specific gravity 1.02 or less, Having at least one of the following, It is a gas at room temperature and room pressure. A method wherein the at least one low-yield carbon black feedstock is a pyrolysis oil present in an amount of 10% to 90% by weight based on the total feedstock, and the at least one first carbon black feedstock present in an amount of 10% to 90% by weight based on the total feedstock.

2. A method for producing carbon black, Introducing a heated gas stream into the furnace carbon black reactor, Mix at least one first carbon black supply material, constituting at least 10% by weight of the total supply material, with the heated gas flow to form a reaction flow, Mix at least one low-yield carbon black supply material, constituting at least 10% by weight of the total supply material, downstream with the existing reaction stream to form the carbon black. To recover the carbon black in the reaction stream, The first carbon black supply material is liquid at room temperature and room pressure and has the following characteristics: - Bureau of Mines Correlation Index (BMCI) 100 or higher, - Atomic H:C ratio of 1.23 or less, -Specific gravity over 1.02, The low-yield carbon black supply raw material has the following characteristics: Bureau of Mines Correlation Index (BMCI) less than 100, or Atomic H:C ratio greater than 1.23, or Specific gravity 1.02 or less, Having at least one of the following, It is a gas at room temperature and room pressure. A method wherein the at least one low-yield carbon black feedstock is ethylene, natural gas, or both, and is present in an amount of 30% to 90% by weight based on the total feedstock, and the at least one first carbon black feedstock is present in an amount of 10% to 70% by weight based on the total feedstock.

3. A method for producing carbon black, Introducing a heated gas stream into the furnace carbon black reactor, Mix at least one first carbon black supply material, constituting at least 10% by weight of the total supply material, with the heated gas flow to form a reaction flow, The carbon black is formed by mixing at least one low-yield carbon black supply material, which constitutes at least 10% by weight of the total supply material, with the existing reaction stream downstream. To recover the carbon black in the reaction stream, The first carbon black supply material is liquid at room temperature and room pressure and has the following characteristics: - Bureau of Mines Correlation Index (BMCI) 100 or higher, - Atomic H:C ratio of 1.23 or less, -Specific gravity over 1.02, The low-yield carbon black supply raw material has the following characteristics: Bureau of Mines Correlation Index (BMCI) less than 100, or Atomic H:C ratio greater than 1.23, or Specific gravity 1.02 or less, Having at least one of the following, It is a gas at room temperature and room pressure. A method wherein the at least one low-yield carbon black supplying material is a bio-based supplying material present in an amount of 10% to 90% by weight based on the total supplying materials, and the at least one first carbon black supplying material present in an amount of 10% to 90% by weight based on the total supplying materials.

4. A method for producing carbon black, Introducing a heated gas stream into the furnace carbon black reactor, A blend comprising at least one first carbon black feed material constituting at least 10% by weight of the total feed material and at least one low-yield carbon black feed material constituting at least 10% by weight of the total feed material is mixed with the heated gas stream to form a reaction stream and form carbon black. To recover the carbon black in the reaction stream, The first carbon black supply material is liquid at room temperature and room pressure and has the following characteristics: - Bureau of Mines Correlation Index (BMCI) 100 or higher, - Atomic H:C ratio of 1.23 or less, -Specific gravity over 1.02, The low-yield carbon black supply raw material has the following characteristics: Bureau of Mines Correlation Index (BMCI) less than 100, or Atomic H:C ratio greater than 1.23, or Specific gravity 1.02 or less, Having at least one of the following, It is a gas at room temperature and room pressure. A method wherein the at least one low-yield carbon black feedstock is a pyrolysis oil present in an amount of 10% to 90% by weight based on the total feedstock, and the at least one first carbon black feedstock present in an amount of 10% to 90% by weight based on the total feedstock.

5. The low-yield carbon black supply raw materials are as follows: a) The Bureau of Mines Correlation Index (BMCI) is less than 95, or b) The gas is at room temperature and room pressure, or c) The atomic H:C ratio is greater than 1.3, or d) The specific gravity is ≤ 1.0, The method according to any one of claims 1 to 4, wherein at least one of the following is the method according to claim 1 to 4.

6. The method according to any one of claims 1 to 4, wherein the low-yield carbon black supply raw material has a specific gravity of less than 1.

02.

7. The method according to claim 3, wherein the bio-based raw material includes at least one of the following: vegetable oil or other plant-derived oil, bio-derived ethanol, plant or animal wax or resin, oil obtained from animal fat, algal oil, oil obtained from the thermal decomposition of sewage sludge or agricultural waste, by-product liquid from the processing of bio-based materials, liquid produced by the hydrothermal liquefaction of biomaterials, crude tall oil, tall oil rosin, tall oil pitch or tall oil fatty acids, oil obtained from recycled materials, oil obtained from the thermal decomposition of low-quality tires, defective tires or tires at the end of their lifespan, oil obtained from the thermal decomposition of discarded or recycled plastic or rubber products, oil obtained from the thermal decomposition of municipal solid waste, or oil obtained from the thermal decomposition of biomass, or any combination thereof.

8. The method according to any one of claims 1 to 7, wherein the at least first carbon black supply raw material comprises one or more of decant oil, slurry oil, coal tar, coal tar derivatives, ethylene cracker residue, or phenol cracker residue.

9. The method according to any one of claims 1 to 8, wherein the first carbon black supply raw material includes a fraction obtained from the distillation of tire pyrolysis oil.

10. The method according to any one of claims 1 or 3 to 9, wherein the low-yield carbon black supply material is in the range of 25 to 90% by weight of the total supply material introduced in the method.

11. The method according to any one of claims 1 to 10, wherein the furnace carbon black reactor comprises a combustion chamber, a throat downstream of the combustion chamber, a reaction chamber downstream of the throat, and a quenching zone downstream of the reaction chamber, and the first carbon black feed material is injected into the combustion chamber of the furnace carbon black reactor, and the low yield carbon black feed material is injected into the throat.

12. The method according to claim 11, wherein the combustion chamber has a certain diameter, and the low-yield carbon black feed material is injected at a distance of at least twice the diameter of the combustion chamber downstream from the position in which the first carbon black feed material is injected.

13. The method according to any one of claims 1 to 12, wherein the furnace carbon black reactor comprises a combustion chamber, a throat downstream of the combustion chamber, a reaction chamber downstream of the throat, and a quenching zone downstream of the reaction chamber, the first carbon black feed material being injected into the throat, and the low yield carbon black feed material being injected after the throat.

14. The method according to claim 13, wherein the furnace carbon black reactor comprises a second throat downstream of the combustion chamber and before the quenching zone, and the low-yield carbon black feed material is injected into the second throat.

15. The method according to any one of claims 1 to 14, wherein the at least one first carbon black feed material is introduced into the furnace carbon black reactor at at least one location upstream from the location where the at least one low-yield carbon black feed material is injected, and at least one separate location downstream from the location of the at least one low-yield carbon black feed material.

16. The method according to claim 15, wherein the amount of the first carbon black feedstock introduced before the location where the at least one low-yield feedstock is injected exceeds 50% of the total amount of the first carbon black feedstock.

17. The method according to any one of claims 1 to 16, wherein the at least one low-yield carbon black feedstock is introduced into the furnace carbon black reactor at at least two separate locations, one of which is downstream of the other.

18. The method according to any one of claims 1 to 17, wherein the at least one first carbon black supplying material is a blend comprising less than 50% by weight of non-high yield carbon black supplying material based on the total weight of the first carbon black supplying material.

19. The method according to any one of claims 1 to 18, wherein the at least one first carbon black supply material comprises a high yield carbon black supply material in an amount of 95% to 100% by weight based on the total weight of the first carbon black supply material.

20. The method according to any one of claims 1 to 19, wherein the at least one low-yield carbon black supplying material comprises 95% to 100% by weight of non-high-yield carbon black supplying material based on the total weight of the low-yield carbon black supplying material.

21. The method according to any one of claims 1 to 20, wherein the at least one low-yield carbon black supplying material is a blend comprising less than 50% by weight of a high-yield carbon black supplying material based on the total weight of the low-yield carbon black supplying material.

22. The method according to any one of claims 1 to 21, wherein the low yield carbon black supply raw material has less than 100 BMCI.

23. The method according to any one of claims 1 to 22, wherein the low-yield carbon black supply raw material has the atomic H:C ratio greater than 1.

23.

24. The method according to any one of claims 1 to 23, wherein the low-yield carbon black supply raw material is a gas at room temperature and room pressure.

25. The method according to any one of claims 1 to 24, wherein the recovered carbon black is carbon black of grade N110, N121, N220, N231, N234, N299, N326, N330, N339, N347, N351, N358, N375, N539, N550, N650, N660, N683, N762, N765, N774, N787, or N990.

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