Method for producing carbon-coated particles from recycled carbon and other particles

Abstract

A method for forming carbon-coated particles is described. The method for forming coated particles includes: heating particles by subjecting them to an energy source which is at least one of a high-temperature gas, microwave energy, induced energy, direct current passing through the particles, electromagnetic radiation, or solar radiation; and supplying a hydrocarbon source in the form of a gas or vapor into a chamber, wherein the hydrocarbon source at least partially decomposes in the chamber to form carbon deposits, thereby coating the heated base particles with the carbon deposits to form carbon-coated base particles. Coated particles produced by one of the methods of the present invention are further described. The advantages achieved by this method are further described.

Description

[Technical Field]

[0001] The present invention relates to methods for coating various particles with carbon coatings, such as recycled carbon and other carbon particles and carbon coatings of other types of particles. The present invention further relates to carbon-coated carbon particles and other carbon-coated particles, and articles containing them.

[0002] There is increasing demand and effort for material recycling in order to avoid materials being discarded as waste and to prevent further depletion of natural resources.

[0003] Therefore, the use of reclaimed carbon (rC) from used tires (or other sources) as a substitute for carbon black (CB) in rubber reinforcement applications may be a promising strategy. However, reclaimed carbon suffers from lower rubber reinforcement properties, such as lower tensile modulus, lower tear strength, and / or lower fatigue life, compared to CB with the same surface area and structure, as measured by OAN. One hypothesis was that the main cause of rC's low rubber reinforcement is its low surface activity. Another cause of low rubber reinforcement is the high proportion of large, poorly dispersed reclaimed particle aggregates present in the rubber as defects in the form of large undispersed particles, which significantly reduces the rubber's tensile strength, tear strength, and fatigue life. Furthermore, another possible cause of the low reinforcement of reclaimed carbon is its compact structure, which is quite different from the more extensive fractal structure of carbon black, which enables high rubber reinforcement. Other materials from recycling or other materials besides reclaimed carbon may have the same or similar problems as reclaimed carbon.

[0004] Therefore, there is a need in the industry to develop processes that can utilize rC and other similar particles, which are not suitable as-is for use as fillers in rubber reinforcement and other applications, to make them suitable or suitable partial substitutes for virgin carbon black. For example, coating recycled carbon particles with a new carbon black-like carbon surface is expected to enhance their surface activity. While several techniques have been attempted to coat particles with carbon, there is a need in the industry to provide alternative methods for coating particles such as rC that do not rely on carbon black reactors or similar technologies.

[0005] All patents and publications mentioned throughout this document are incorporated herein by reference in their entirety. [Overview of the project]

[0006] The feature of this invention is to provide a method for coating recycled carbon with a carbon layer.

[0007] An additional feature of the present invention is to provide a method for coating particles other than recycled carbon, such as non-ASTM reinforced grade particles, with a carbon layer.

[0008] A further feature of the present invention is to provide a method for making recycled carbon a more viable material for use as a reinforcing grade material in applications such as rubber.

[0009] A further feature of the present invention is to provide a method for modifying one or more properties of recycled carbon or other particles to make them a more viable material for use as a reinforcing grade filler.

[0010] Furthermore, a feature of the present invention is to provide a method for processing recycled carbon and / or other carbon particles and / or other non-ASTM reinforced grade particles and non-carbon-containing particles, thereby imparting particles equivalent to, but not limited to, acceptable tensile modulus, hysteresis (measured by tanδ), tear strength, and / or fatigue life compared to virgin carbon black.

[0011] A further feature of the present invention is to provide a method for processing recycled carbon and / or other carbon particles and / or other non-ASTM reinforced grade particles and non-carbon-containing particles, thereby imparting to the particles excellent rubber reinforcement properties, including but not limited to, an acceptable tensile modulus, hysteresis (measured by tanδ), tear strength, and / or fatigue life, compared to the untreated starting material.

[0012] An additional feature of the present invention is to provide carbon-coated recycled carbon and / or carbon-coated particles having one or more different properties compared to non-carbon-coated recycled carbon (e.g., recycled carbon or pulverized recycled carbon).

[0013] An additional feature of the present invention is to provide a method for producing carbon-coated recycled carbon and / or carbon-coated particles that reduce or completely eliminate carbon dioxide emissions.

[0014] An additional feature of the present invention is to provide a method for producing carbon-coated recycled carbon and / or carbon-coated particles having low greenhouse gas intensity and / or a high amount of recycled content.

[0015] To achieve these and other advantages, and in accordance with the objectives of the present invention, as embodied and broadly described herein, the present invention relates in part to a method for forming carbon-coated base particles, for example, carbon-coated carbon particles. More specifically, one method relates to a method for forming carbon-coated base particles, the method comprising introducing base particles into a chamber and subjecting the base particles to an energy source which is at least one of a high-temperature gas, microwave energy, induced energy, direct current passing through the base particles, electromagnetic radiation, or solar radiation to form heated base particles. The method comprises supplying a hydrocarbon source which includes or is a gas or vapor into the chamber. The hydrocarbon source is at least partially thermally decomposed in the chamber to form a carbon deposit, thereby coating the heated base particles with the carbon deposit to form carbon-coated base particles. Exemplary base particles used in the method may be or may include recycled carbon particles or other carbon particles which are non-ASTM reinforced grade particles.

[0016] The present invention also relates to utilizing the above method using, for example, particles with a lower amount of carbon in the particles compared to recycled carbon.

[0017] The present invention further relates in part to a method for forming carbon-coated precipitated silica particles. The method may include introducing precipitated silica particles into a chamber and subjecting the precipitated silica particles to microwave energy or other forms of energy as detailed herein to form heated precipitated silica particles. The method may further include supplying a hydrocarbon source, which includes or is a gas or vapor, into the chamber. The hydrocarbon source is at least partially thermally decomposed in the chamber to form carbon deposits, thereby coating the heated precipitated silica particles with the carbon deposits to form carbon-coated precipitated silica particles.

[0018] Furthermore, the present invention relates in part to carbon-coated particles and carbon-coated particles formed by the method of the present invention.

[0019] The present invention further relates to products and / or articles such as, but not limited to, tires, tire components, and / or elastomeric composites formed at least in part from the coated particles of the present invention.

[0020] It should be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive, serving to further illustrate the scope of the claimed invention.

[0021] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate various features of the invention and, together with the detailed description, serve to explain the principles of the invention.

Brief Description of the Drawings

[0022] [Figure 1] FIG. 1 is a schematic cross-sectional view of an example of a system having a chamber suitable for use in the method of the present invention.

[0023] [Figure 2] FIG. 2 is a schematic cross-sectional view of a further example of a two-chamber system suitable for use in the method of the present invention.

[0024] The drawings are not to scale and are provided as simplified diagrams and do not necessarily show all possible embodiments or components that may exist.

Modes for Carrying Out the Invention

[0025] The present invention relates to a method of carbon coating various types of particles, the carbon-coated particles obtained thereby, and the simultaneous generation of hydrogen. The particles to be coated can be carbon particles. The particles to be coated can be particles having a carbon content. The particles to be coated can be non-ASTM reinforced grade particles. The carbon particles that can be coated include recycled carbon. The particles to be coated can be non-carbon-containing particles such as silica particles, preferably precipitated silica particles.

[0026] The present invention relates to a method for forming carbon-coated base particles. The method comprises, comprises, essentially consists of, or comprises the following: introducing base particles into a chamber; and subjecting the base particles to an energy source which is at least one of microwave energy, induced energy, direct current passing through the base particles, electromagnetic radiation, or solar radiation, to form heated base particles. The method comprises, comprises, essentially consists of, or comprises the following hydrocarbon source which includes, comprises, essentially consists of, or comprises the following hydrocarbon source which includes, includes, essentially consists of, or comprises the following hydrocarbon source which includes, includes, essentially consists of, or comprises the following hydrocarbon source which includes, includes gas or vapor. The hydrocarbon source is at least partially thermally decomposed in the chamber to form carbon deposits, thereby coating the heated base particles with the carbon deposits to form carbon-coated base particles. The base particles may comprise, essentially consist of, consist of, or include the following hydrocarbons: a) recycled carbon particles and / or b) other carbon particles which are non-ASTM reinforced grade particles. The temperature of the heated base particles may be at least 800°C, at least 900°C, at least 1000°C, at least 1100°C, at least 1200°C, at least 1300°C, at least 1400°C, or at least 1500°C, for example, 900-1200°C or 1300-1600°C.

[0027] The base particles introduced into the chamber can be of various types of carbon particles. Furthermore, as will be described later, the particles may be carbon-containing particles or carbon-free particles instead of carbon particles. For the purposes of the present invention, carbon particles are particles that consist mainly of carbon. Carbon particles generally have carbon as their main component (for example, carbon is present in amounts of at least 75% by weight, at least 80% by weight, at least 85% by weight, at least 90% by weight, at least 95% by weight, at least 98% by weight, at least 99% by weight, for example, 75% to 95% by weight, or 75% to 100% by weight, based on the total weight of the particles). Examples of carbon particles include, but are not limited to, recycled carbon particles (rC). rC can optionally be deaggregated (i.e., deaggregated recycled carbon, or deaggregated rC deaggregated from recycled carbon aggregates (i.e., recycled aggregates)).

[0028] rC, for example, rC aggregates, are commercially available. Generally, rC aggregates result from the thermal decomposition of tires and / or other rubber or plastic materials containing filler or reinforcing materials such as carbon black. rC is primarily produced from carbon black used to reinforce rubber or plastics. The raw tire and other rubber or other raw material materials contain thermally decomposable components, such as rubber components, and at least some of these components are thermally decomposed by the high temperatures described herein in the method of the present invention to produce thermally decomposed carbon. The thermally decomposed carbon is processed to remove at least one macroscopic contaminant, such as fibers or wires, to produce recycled carbon (rC). rC can optionally be reduced in average particle size by jet grinding or by grinding as described in International Publication No. 2023122582, the entire contents of which are incorporated by reference.

[0029] Non-ASTM reinforced grade carbon particles are carbon particles that do not meet one of the ASTM 100, 200, or 300 series carbon black fillers, or one of the ASTM 500, 600, or 700 series carbon black fillers. Examples of such carbon particles may be carbon black, but also include, but are not limited to, solid hydrothermal carbon (HTC), silicon-treated carbon black, silica-coated carbon black, graphene, reduced graphene oxide, single-walled carbon nanotubes, multi-walled carbon nanotubes, carbon nanostructures, carbon black-coated particles, and biochar. Furthermore, the above-mentioned recycled carbon particles also do not meet this ASTM standard.

[0030] Instead of carbon particles, other types of particles with some carbon content (for example, 10% to 75% by weight, or 10% to 60% by weight, or 10% to 50% by weight, or 10% to 40% by weight, based on the total weight of the particles) can be used. For example, the particles may be graphene oxide, lignin, or nanocrystalline cellulose. Other examples of carbon-containing particles include bio-based particles. Specific examples of bio-based particles include, but are not limited to, polysaccharides or artificial polysaccharides.

[0031] Instead of carbon particles, particles with little to no carbon content (e.g., less than 10% by weight of carbon). For example, the particles may be precipitated silica, rice husk silica, clay, nanoclay, diatomaceous earth, metal oxides, or metal carbonates.

[0032] As an option, in order to support more effective heating of the base particles and to enable more uniform or more efficient coating of the base particles, the base particles may have one or more of the following particle size parameters. A: Volume-weighted average aggregate size of less than 2 microns (e.g., less than 1.75 microns, less than 1.5 microns, less than 1 micron, less than 0.9 microns, less than 0.8 microns, less than 0.7 microns, less than 0.6 microns, e.g., 0.5 microns to 1.9 microns, 0.5 microns to 1.7 microns, 0.5 microns to 1.5 microns, 0.5 microns to 1.25 microns, 0.5 microns to 1 micron, 0.5 microns to 0.8 microns, 0.6 microns to 1.9 microns, 0.7 microns to 1.9 microns, 0.8 microns to 1.9 microns, 0.9 microns to 1.9 microns, 1 micron to 1.9 microns); B: D10 aggregate size less than 400nm (e.g., less than 375nm, less than 350nm, less than 325nm, less than 300nm, less than 275nm, less than 250nm, less than 225nm, less than 200nm, less than 175nm, less than 150nm, e.g., 140nm~390nm, 150nm~390nm, 160nm~390nm, 170nm~390nm, 180nm~390nm, 190nm~390nm, 200nm~390nm, 140nm~380nm, 140nm~350nm, 140nm~300nm, 140nm~250nm, 140nm~200nm); C: D25 aggregate size less than 1 micron (e.g., less than 0.9 microns, less than 0.8 microns, less than 0.7 microns, less than 0.6 microns, less than 0.5 microns, less than 0.4 microns, less than 0.3 microns, less than 0.25 microns, less than 0.2 microns, e.g., 0.2 microns to 0.9 microns, 0.3 microns to 0.9 microns, 0.4 microns to 0.9 microns, 0.5 microns to 0.9 microns, 0.2 microns to 0.8 microns, 0.2 microns to 0.5 microns, 0.2 microns to 0.4 microns); D: D50 aggregate size of less than 4 microns (e.g., less than 3.5 microns, less than 3 microns, less than 2.5 microns, less than 2 microns, less than 1.5 microns, less than 1 micron, less than 0.75 microns, less than 0.5 microns, less than 0.4 microns, less than 0.35 microns, e.g., 0.35 microns to 3.9 microns, 0.4 microns to 3.9 microns, 0.5 microns to 3.9 microns, 0.6 microns to 3.9 microns, 0.7 microns to 3.9 microns, 0.8 microns to 3.9 microns, 0.35 microns to 3.5 microns, 0.35 microns to 3 microns, 0.35 microns to 2.5 microns, 0.35 microns to 2 microns, 0.35 microns to 1.5 microns, 0.35 microns to 1 micron, 0.35 to 0.9 microns); E: D75 aggregate size less than 4.5 microns (e.g., less than 4 microns, less than 3.5 microns, less than 3 microns, less than 2.75 microns, less than 2.5 microns, less than 2.25 microns, less than 2 microns, less than 1.75 microns, less than 1.5 microns, less than 1.25 microns, less than 1 micron, e.g., 1 micron to 4 microns, 1 micron to 3.5 microns, 1 micron to 3 microns, 1 micron to 2.5 microns, 1 micron to 2 microns, 1 micron to 1.5 microns, 1.1 microns to 4 microns, 1.2 microns to 3.5 microns, 1.3 microns to 3 microns); F: D90 aggregate size less than 5 microns (e.g., less than 4.5 microns, less than 4 microns, less than 3.5 microns, less than 3 microns, less than 2.75 microns, less than 2.5 microns, less than 2.25 microns, less than 2 microns, e.g., 2 microns to 4.5 microns, 2 microns to 4.25 microns, 2 microns to 4 microns, 2 microns to 3.5 microns, 2 microns to 3 microns, 2.25 microns to 4 microns, 2.5 microns to 4 microns, 2.75 microns to 4 microns); G: Heterogeneity Index (HI) for values ​​less than 20 (e.g., less than 15, less than 10, less than 9, less than 8, less than 7, less than 6, less than 5, less than 4, e.g., 4-15, 4-10, 4-9, 4-7, 4-6, 5-15, 6-15, 7-15, 8-12) (defined as the ratio of volume-weighted average aggregate size to number-weighted average aggregate size); H: Mass % > 1 micron with less than 60% (e.g., less than 55%, less than 50%, less than 45%, less than 40%, less than 40%, less than 35%, less than 30%, less than 25%, less than 20%, less than 15%, less than 10%, e.g., 10%~55%, 10%~50%, 10%~45%, 10%~40%, 10%~35%, 10%~30%, 10%~25%, 15%~45%, 20%~45%, 25%~45%, 30%~45%). The base particles may have one or all of the aggregate size parameters described above. Any combination of A to H is possible (for example, one or more of A to H, two or more of A to H, three or more of A to H, four or more of A to H, five or more of A to H, six or more of A to H, seven or all of A to H).

[0033] Compared to rC aggregates, deaggregated rC may exhibit a reduction of 10%, 20%, 50%, or 75% or more in any one or more of the following: average aggregate size, D10 aggregate size, D25 aggregate size, D50 aggregate size, D75 aggregate size, D90 aggregate size, HI, and / or mass% > 1 micron.

[0034] rC may contain a certain amount of non-carbon material. For example, rC may contain 1% to 20% or more by weight of non-carbon material or components (relative to the total weight of rC), such as, but not limited to, silica particles and / or ZnO.

[0035] With respect to the chamber, the chamber can have any suitable shape and size and can be constructed of a material that allows energy from an energy source to come into contact with base particles, resulting in heated base particles and causing the hydrocarbon source to thermally decompose. For example, the chamber may be a fluidized bed reactor, an ablative pyrolysis reactor, a vacuum pyrolysis reactor, a fixed-bed fall reactor, or a solar pyrolyzer.

[0036] Regarding the energy sources to which the base particles are exposed to produce heated base particles, these energy sources include, but are not limited to, exposure to high-temperature gases, resistance heating, microwave energy, induction energy, direct current passing through the base particles, electromagnetic radiation, or solar radiation. Heating of the particles can be carried out by dielectric heating or induction heating. In the case of methods that rely on passing an electric current through the base particles, it is preferable that the base particles are conductive.

[0037] Microwave energy can be obtained from any type of microwave generator. For example, a microwave generator may be a magnetron, which includes a heated filament and a vacuum-sealed chamber with a magnetic field. When the filament is heated, it emits electrons accelerated by the magnetic field, generating a stream of electrons moving toward the anode. As the electrons pass through the resonant cavity, they oscillate, generating a high-frequency electromagnetic field, which is then directed out of the cavity by an antenna. Other types of microwave generators include klystrons, traveling wave tubes, and solid-state devices. The microwave generator can be located inside or adjacent to the chamber. Commercial examples include, but are not limited to, the MUEGGE microwave generator, CEM microwaves such as the CEM LABWAVE and AIRWAVE models, and the THERMEX THERMATRON microwave generator.

[0038] A microwave generator can produce electromagnetic radiation having a frequency of at least 0.5 GHz, for example, between 0.5 GHz and 300 GHz or higher.

[0039] Microwave generators can operate at power levels ranging from 300 watts to over 4 MW, for example, 1 kW to 1 MW, 10 kW to 500 kW, 100 kW to 400 kW, or 200 kW to 300 kW.

[0040] Induction energy can be provided by induction heaters. Induction heating is a non-contact method of heating a material by utilizing a strong magnetic field that induces alternating current (AC) in the material, which excites atoms in the material and heats it. Induction heaters incorporate a coil that is powered directly from a power source. The coil, also known as an inductor, is used to transfer energy from the power unit to the material. Inductors range in complexity from simple wound solenoids, which consist of numerous windings of copper tubing wound around a mandrel, to precision items machined from solid copper, brazed together, and soldered. Commercial examples of such induction heaters include, but are not limited to, the EASYHEAT and EKOHEAT induction heating systems by AMBRELL, the INDUCTOFORGE induction heating system by INDUCTOHEAT, and the HEATLINE induction heater by ENRX.

[0041] The induction heater can be operated at a frequency of at least 5 kHz, for example, 5 kHz to 500 kHz or higher. The induction heater can be operated at an induction heater energy level of at least 50 MJ / kg, for example, 50 MJ / kg to 250 MJ / kg or higher (where kg is the amount of particles processed in the chamber).

[0042] A DC power source can be used to heat the base particles by passing a DC current through them. The DC power source can be a battery, a power supply, an electrochemical cell, or a renewable power system.

[0043] A DC power supply can have a voltage of at least 1V to 400V or more. For example, the voltage of a DC power supply may be 10V to 300V, 50V to 200V, or 100V to 150V.

[0044] Electromagnetic radiation includes electromagnetic field waves such as radio waves, infrared rays, microwaves, visible light, ultraviolet rays, X-rays, induction heating, and gamma rays. Examples of microwave generators and induction heating generators are provided above. Other devices that generate electromagnetic radiation include infrared heaters, lasers, and high-frequency heaters.

[0045] The frequency and power required for an electromagnetic radiation generator depend on the type of electromagnetic radiation being generated. For example, the frequency range of an infrared heater may be 1 μm to 100 μm, and the power level may be in the range of 1 W to 100 kW. The frequency range of a high-frequency heater may be 1 kHz to 100 MHz, and the power level may be in the range of 1 W to 100 kW. The frequency of a laser system may be 1 tHz to 100 tHz, and the power level may be in the range of 1 mW to 100 kW.

[0046] Solar radiation can be used to heat particles such as base particles. This invention utilizes a solar radiation concentrate that heats base particles by increasing the intensity of solar radiation. Examples of solar radiation concentrates include solar heat collectors, solar furnaces, solar ovens, and solar kilns. These devices use parabolic troughs, dish collectors, tower collectors, mirrors, lenses, reflectors, etc., to expand and concentrate the heat of solar radiation onto the base particles.

[0047] The energy source used can be arbitrarily selected and can be generated from renewable energy sources such as renewable electricity (e.g., solar power, wind power, etc.).

[0048] With respect to hydrocarbon sources, as shown, hydrocarbon sources include, comprise, essentially consist of, consist of, or are gases or vapors supplied into the chamber. A hydrocarbon source can be thought of as a carbon source that can be thermally decomposed to form carbon deposits.

[0049] The hydrocarbon source may include, contain, or be composed of natural gas.

[0050] Other examples of hydrocarbon sources include, but are not limited to, propane. Hydrocarbon sources include, or may include, bio-oils, recycled oils, sustainable oil vapors; biofuels or by-products of biochemical production; or tires, such as oils derived from tire pyrolysis, oils derived from plastic pyrolysis or recycling, or oils derived from hydrothermal liquefaction or paper processing.

[0051] Other specific examples of hydrocarbon sources include the following: Glycerin from the production of biodiesel. Other hydrocarbon by-products of biofuel production, such as distilled corn oil. • Volatile fraction of hydrocarbons from hydrothermal liquefaction Crude tall oil, tall oil pitch, turpentine, resin, or volatile components of tall oil fats. ·Waste cooking oil. • Biomethane or renewable natural gas produced from the decomposition of sludge, sewage, agricultural waste, or landfill materials. • Lignin-derived oil. • Vegetable oil, edible or non-edible (e.g., jatropha oil). Tire pyrolysis oil derived from the thermal decomposition of tires or rubber articles made from natural rubber. Hydrocarbons derived from seaweed, algae, or other non-crop plants. • Hydrocarbons derived from or produced by cyanobacteria. • Hydrocarbons derived from black liquor in paper processing. • Volatile oils derived from animal waxes or fats, such as lanolin, lard, or animal fat. • Oils obtained from animal processing by-products, such as pyrolysis, thermal decomposition, or rendering of turkey carcasses. Recycled oil or volatile hydrocarbons may be the following: • Volatile components of used engine oil. • Oil or hydrocarbon gas derived from the thermal decomposition of plastic waste. • Oil or hydrocarbon gas derived from the thermal decomposition of municipal solid waste. Oil or hydrocarbon gases derived from the thermal decomposition of tires at the end of their lifespan or scrap tires.

[0052] The hydrocarbon source may be from one source or a mixture of two or more sources.

[0053] The hydrocarbon source can be supplied to the chamber as one or more feeds. For example, the hydrocarbon source can be supplied (e.g., injected) into the chamber by one or more jets or feed lines. Multiple feed lines may be arranged or distributed around the chamber so that the hydrocarbon source is uniformly distributed within the chamber, which may result in a better distribution of carbon deposits onto the base particles resulting from the thermal decomposition of hydrocarbons.

[0054] The amount of hydrocarbon source may be based on the amount of particles being coated and / or the desired coating thickness, and may depend on the carbon content and thermal decomposition behavior of the hydrocarbon source. For example, the amount of hydrocarbon source may be 0.01 kg or more per kg of particles, or 0.1 kg or more per kg of particles, or at least 0.15 kg per kg of particles. Other amounts less or more than these ranges can also be used. The hydrocarbon source or the gas or vapor containing the hydrocarbon source may be a gas or vapor. The amount of hydrocarbon source containing the gas or vapor may be any amount. The amount of hydrocarbon source in the gas or vapor may be, for example, at least 25 vol%, or at least 50 vol%, or at least 75 vol%, or at least 80 vol%, or at least 90 vol%, or at least 95 vol%, or at least 99 vol%.

[0055] The amount of hydrocarbon source to be pyrolyzed is preferably 100% by volume or about 100% by volume. Amounts less than 100% by volume are possible (e.g., 50% to 99% by volume, or 75% to 99% by volume, or 85% to 99% by volume, or other amounts, based on the total volume of hydrocarbon source present). If an amount of hydrocarbon source is not pyrolyzed, these unused amounts may optionally be recycled and used in subsequent batches to form carbon-coated particles.

[0056] Alternatively, the hydrocarbon may be heated in addition to, or instead of, heating the base particles. The hydrocarbon may be heated to a temperature of at least 800°C, at least 900°C, at least 1000°C, at least 1100°C, at least 1200°C, at least 1300°C, at least 1400°C, or at least 1500°C, for example, between 900 and 1200°C or 1300 and 1600°C.

[0057] As an option, an oxidizing atmosphere may be present in the chamber for at least a portion of the residence time the base particles spend in the chamber. An oxidizing atmosphere can be achieved at least by introducing water into the chamber. Preferably, the oxidizing atmosphere is present in the early or initial stages of the residence time of the base particles in the chamber (e.g., during the first half of the residence time, or the first third, or the first quarter). Preferably, oxygen is not introduced into the chamber during the thermal decomposition of the hydrocarbon source, thus delaying or preventing the generation of carbon dioxide and carbon monoxide. More preferably, carbon dioxide and carbon monoxide are not introduced into the chamber during thermal decomposition, thus reducing or eliminating carbon dioxide and / or carbon monoxide in the gas stream discharged from the chamber after thermal decomposition.

[0058] Alternatively, the method of the present invention may include steam oxidation of the base particles within the chamber. Steam oxidation can occur at any point during the residence time within the chamber. Preferably, this option occurs early or in the initial stages of the residence time of the base particles within the chamber (e.g., during the first half of the residence time, or the first third, or the first quarter).

[0059] As an option, the method of the present invention may further include, in a second step (subsequent step), heating the carbon-coated particles in a neutral or reducing atmosphere in either the same chamber or a different chamber. Thus, once the base particles are coated with carbon by the method of the present invention, this further step may occur. The further heating may be achieved with the same or a different energy source as used in the coating step, or with a completely different energy source, such as, but not limited to, a rotary kiln, a furnace, a carbon black reactor (e.g., a multi-stage carbon black reactor or a furnace carbon black reactor), or an improved carbon black reactor (e.g., a carbon black reactor without injection ports for carbon black formation feedstock). The heating chamber may be an insulated chamber. The rotary kiln may be a direct combustion rotary kiln or an indirect combustion rotary kiln. The rotary kiln may be a Feeco rotary kiln.

[0060] The heating in this optional second step may be at a temperature of at least 300°C, or at least 500°C, or at least 800°C. The heating may depend on the function of the heating, if utilized. If heating is used to promote or further promote thermal decomposition, higher heating temperatures may be more desirable (at least 500°C or at least 800°C). If heating is used to promote or further promote the removal of volatiles, lower heating temperatures may suffice (e.g., at least 300°C). This optional heating may be beneficial in that it can evaporate or otherwise remove non-carbon substances, or evaporate or otherwise remove at least a portion of these types of substances. The residence time in this optional second step may be at least 10 seconds, or at least 10 minutes, or at least 1 to 2 hours.

[0061] As an option, a non-reacting carrier gas or non-reactive carrier gas may be present as a mixture with the hydrocarbon source, introduced simultaneously into the chamber, or introduced before and / or after the introduction of the hydrocarbon source. Examples of such gases include, but are not limited to, nitrogen, argon, helium, or any combination thereof. The amount of this arbitrary gas can be up to 20:80 (volume ratio of hydrocarbons to non-reactive gas). Lower or higher ratios are also possible.

[0062] As shown, the hydrocarbon gas can be introduced into the chamber at two or more locations within the chamber. Optionally, an optional nonreactive carrier gas can be introduced into the chamber at two or more locations within the chamber, either separately or together with the hydrocarbon gas.

[0063] Regarding the introduction or supply of base particles to the chamber, the base particles can be supplied to the chamber in batches, continuously, or semi-continuously. For example, the base particles may be placed on a tray and then introduced into the chamber. Alternatively, the base particles may be supplied into the chamber using a conveyor or other mechanical device that moves or supplies particles from one place to another.

[0064] The rate at which base particles are supplied to the chamber may be any rate and may depend on the size of the chamber and energy source. Examples of preferred supply rates include particles at least 100 kg / hr, or at least 250 kg / hr, or at least 500 kg / hr, or at least 750 kg / hr, or at least 1000 kg / hr, or at least 2000 kg / hr, or at least 3000 kg / hr, or at least 4000 kg / hr, or at least 5000 kg / hr. The base particles may be located or placed on a fixed floor within the chamber, or placed on a tray, mobile platform, or conveyor for introduction into the chamber.

[0065] As an option, the base particles could be on a moving floor that passes through the chamber.

[0066] In the method of the present invention, when the hydrocarbon source is thermally decomposed and a carbon deposit is formed, the carbon deposit can completely cover the base particles. Alternatively, carbon can be deposited almost completely on the base particles such that at least 75%, or at least 80%, or at least 90%, or at least 95%, or at least 98%, or at least 99% of the exposed outer surface area of ​​the base particles is covered by the carbon deposit.

[0067] The resulting carbon-coated base particles have a ratio of the area of ​​the Raman D band to the area of ​​the Raman G band of 0.5 to 2.45, for example, 1 to 2.45 or 1.5 to 2.45 (I D / I / G ) may have. The Raman measurements are based on Gruber et al., "Raman Studies of Heat-Treated Carbon Blacks", Carbon Vol.32(7), pp.1377-1382, 1994, which is incorporated herein by reference. The Raman spectra of carbon are shown as the "D" and "G" bands, respectively, at approximately 1340 cm⁻¹. -1 and 1580cm -1 It includes two main "resonance" bands. Generally, the D band is irregular sp 2 Due to carbon, the G band is graphite or "regular" sp 2 It is thought to be caused by carbon. Therefore, the D / G band ratio (I D / I G The decrease (also known as) corresponds to a more ordered crystal structure.

[0068] With respect to the coating on the base particles, the coating may be uniformly or substantially uniformly the same thickness around the outer surface of the base particles. For example, the thickness around the outer surface of the base particles may vary (on average) to less than 20%, less than 15%, less than 10%, or less than 5% of the thickness around the outer surface of the base particles. This determination can be based, for example, on the analysis of 5% by weight, 2% by weight, or 1% by weight of coated base particles in a batch.

[0069] The carbon deposit covering ranges from approximately 0.5 nanometers (nm) to approximately 500 nm or more, or approximately 0.75 nm to 500 nm or more, or approximately 1 nm to 500 nm or more, for example, 0.5 nm to 450 nm, 0.5 nm to 400 nm, 0.5 nm to 350 nm, 0.5 nm to 300 nm, 1 nm to 250 nm, 1 nm to 200 nm, 1 nm to 150 nm, 1 nm to 125 nm, 1 nm to 100 nm, 1 nm to 75 nm, 1 nm to 50 nm, 1 nm to 25 nm, 1 nm to 20 nm, 1 nm to 15 nm, 1 nm to The average thickness can be 10 nm, 1 nm to 7.5 nm, 1 nm to 5 nm, 1 nm to 2.5 nm, 0.5 nm to 1 nm, 0.5 nm to 5 nm, 10 nm to 500 nm, 50 nm to 500 nm, 100 nm to 500 nm, 250 nm to 500 nm, 1 nm to 500 nm, 7.5 nm to 50 nm, 10 nm to 50 nm, 1.25 nm to 5 nm, 1.5 nm to 5 nm, 2 nm to 5 nm, 2.5 nm to 5 nm, 3 nm to 5 nm, or any range based on any two values ​​listed herein. The average thickness can be based, for example, on the analysis of 5 wt%, 2 wt%, or 1 wt% of the carbon-coated particles in a batch.

[0070] As an alternative, the method of the present invention may occur when the carbon deposits do not cover 100% of the base particles, but rather at least partially cover the base particles. In partial coverage, for example, 25% to 75% or 50% to 95% (on average) of the outer surface of the base particles are covered with carbon deposits.

[0071] The residence time of base particles in the chamber is generally sufficient time for the carbon deposit to form and coat the base particles. The residence time may depend on the amount of base particles being heated, the type of energy source, the power or frequency of the energy source, the hydrocarbon source, and the heating temperature. Base particles can have residence times in the chamber ranging from, for example, 1 second to 3 hours or more. The dwell time can range from 1 second to 2.75 hours, 1 second to 2.5 hours, 1 second to 2.25 hours, 1 second to 2 hours, 1 second to 1.75 hours, 1 second to 1.5 hours, 1 second to 1.25 hours, 1 second to 1 hour, 1 second to 45 minutes, 1 second to 30 minutes, 1 second to 15 minutes, 1 second to 10 minutes, 1 second to 5 minutes, 1 second to 60 seconds, 1 second to 30 seconds, 5 seconds to 2 hours, 5 seconds to 1 hour, 5 seconds to 30 minutes, 5 seconds to 15 minutes, 5 seconds to 3 hours, 30 seconds to 3 hours, 1 minute to 3 hours, 5 minutes to 3 hours, 30 minutes to 3 hours, etc.

[0072] Alternatively, the method of the present invention can be carried out in the absence of a catalyst.

[0073] Alternatively, the method of the present invention may be carried out in the absence of introduced oxygen or an oxygen-containing gas (for example, a gas in which oxygen constitutes more than 10% by volume, more than 15% by volume, or more than 20% by volume based on the total volume of the gas).

[0074] As an option, the method of the present invention may produce no carbon dioxide or carbon monoxide at all, or essentially no carbon dioxide or carbon monoxide at all (for example, the amount of carbon dioxide and / or carbon monoxide produced is less than 0.5 kg total of CO2 and CO per 1 kg of carbon-coated particles). Alternatively, hydrogen gas may be generated by the decomposition of hydrocarbons. This hydrogen gas is thus produced without any or essentially no carbon dioxide, and the carbon from hydrocarbons is deposited as a solid on the base particles. For example, the gas discharged from the chamber may contain a maximum of 0.5 kg total of carbon dioxide and carbon monoxide per 1 kg of carbon-coated particles, for example, a maximum of 0.2 kg total of carbon dioxide and carbon monoxide per 1 kg of carbon-coated particles, or a maximum of 0.1 kg total of carbon dioxide and carbon monoxide per 1 kg of carbon-coated particles. The resulting hydrogen gas can be separated from other gases discharged from the chamber by any technique known to those skilled in the art (e.g., pressure swing adsorption, hydrogen permeable ceramic membrane, etc.).

[0075] The gas discharged from the chamber may be at least 50% by volume of hydrogen. In embodiments where no oxygen-containing gas, vapor, or other carrier gas is introduced into the chamber, or only in limited amounts, the gas discharged from the chamber may be at least 60% by volume, at least 70% by volume, at least 80% by volume, or at least 90% by volume, for example, 60% to 90% by volume, 70% to 95% by volume, or 80% to 99% by volume of hydrogen. The resulting hydrogen can be used as a fuel source. In some embodiments, the gas discharged from the chamber can be used as a fuel source without further purification processes.

[0076] The base particles heated by the energy source in the chamber are, for example, at least 800°C, or at least 900°C, or at least 1200°C, or at least 1500°C, for example, 800°C to 1600°C, or 800°C to 1400°C, or 800°C to 1300°C, or 800°C to 1200°C, or 800°C to 1100°C, or 800°C to 1000°C, or 800°C to 900°C, or 900°C to 1500°C, or 1000°C to 1500°C, or 1100°C to It is heated to 1500°C, or 1200°C to 1400°C, or 1200°C to 1500°C, or 850°C to 1500°C, or 875°C to 1500°C, or 950°C to 1500°C, or 1050°C to 1500°C, or 1150°C to 1500°C, or 1250°C to 1500°C, or 1350°C to 1500°C, or 800°C to 1450°C, or 850°C to 1450°C, or above 1500°C, or any endpoint from any combination of these ranges.

[0077] Here, and throughout (for any other steps), references to temperatures related to the heating of particles are temperatures calculated based on thermodynamic calculations of the material being introduced into the reactor (without including any heat loss through the chamber or reactor walls). Optionally, the chamber may have two or more zones where heating takes place. If there are two or more zones for a heating chamber, one or more of the other zones may be used as additional heat treatment zones (i.e., having zone temperatures of at least 300°C, or at least 500°C, or at least 800°C), or as quenching zones and / or for other purposes. If more than one zone is used to achieve zone temperatures of at least 300°C, or at least 500°C, or at least 800°C, each of these zones may have the same, similar, or different heating temperatures. The residence times of each of these zones, if used, may be the same, similar, or different. The temperature and / or residence time of each of these zones, if utilized, may differ from each other by no more than 1%, 5%, 10%, 20%, 30%, 40%, 50%, 75%, or at least one of the percentages provided herein.

[0078] If the chamber has two or more heating zones, the energy sources used in each zone may be the same or different.

[0079] Optionally, the chamber may comprise at least a first chamber and a second chamber. In such a configuration, in the first chamber, in the complete absence of a hydrocarbon source, the base particles are supplied to at least one of an energy source (e.g., microwave energy or induced energy) so that the base particles reach an average surface temperature of at least 800°C, at least 900°C, at least 1000°C, at least 1100°C, at least 1200°C, at least 1300°C, at least 1400°C, at least 1500°C, or at least 1600°C (e.g., 800°C to 1600°C, or 800°C to 1500°C, or 1000°C to 1300°C) to obtain heated base particles. The heated base particles are then transported to a second chamber (and any other feature having a hydrocarbon source) where the hydrocarbon source is supplied.

[0080] In the second chamber, further heating of the base particles is optional. The high temperature at which the particles can be heated may be sufficient to avoid the need for further heating in the second chamber, and this temperature may cause thermal decomposition of the hydrocarbon source within the second chamber. Optionally, but not mandatory, the base particles in the second chamber may be subjected to further heating by an additional energy source or the same energy source as in the first chamber. The type of energy source may be the same as or different from the energy source used in the first chamber.

[0081] If an additional heat source is used in the second chamber, the heat source can maintain the heated base particles at an average surface temperature of at least 800°C, at least 900°C, at least 1000°C, at least 1100°C, at least 1200°C, at least 1300°C, at least 1400°C, at least 1500°C, or at least 1750°C, or at least 2000°C (e.g., 800°C to 2200°C, or 800°C to 2000°C, or 1000°C to 1800°C). Optionally, the heated base particles are located on a moving bed in the second chamber.

[0082] As an option, at least one catalyst can be used during the method of the present invention. For example, the catalyst may be a metal catalyst or an inorganic catalyst. As a further option, recycled iron or limestone may be used and applied to at least a portion of the surface of the base particles before being used as an energy source. In the method of the present invention, the catalyst is preferably covered by a carbon deposit that coats the base particles and is therefore not exposed or visible on the surface of the coated base particles. The amount of catalyst may be the same as that used in conventional or ordinary waste contamination processes. The catalyst may be, but is not limited to, a catalytic system material having potassium, sodium, magnesium, calcium, aluminum, nickel, iron, or one or more of these metals, or any combination thereof. It may be advantageous to intentionally add a known pyrolysis catalyst, such as iron, in amounts up to, for example, 10% by mass (other amounts may also be used).

[0083] If two or more chambers are used, the option is that the base particles may be at least partially deaggregated in the first chamber if they have not already been deaggregated.

[0084] When two or more chambers are used, the chambers, for example, the first chamber, may be of different sizes in terms of volume compared to the second chamber. For example, the first chamber may have a volume at least 25% smaller, or at least 50% smaller, than the volume of the second chamber (for example, 25% to 75% smaller than the volume of the second chamber).

[0085] By applying some of the main embodiments of the present invention to particles other than carbon particles, the present invention can provide a method for carbon-coating non-carbon particles, such as silica, preferably precipitated silica particles.

[0086] For example, the present invention further relates to a method for forming carbon-coated precipitated silica particles. The method comprises introducing precipitated silica particles into a chamber and subjecting the precipitated silica particles to one of the energy sources described herein, such as microwave energy or induced energy, to form heated precipitated silica particles. The method further comprises supplying a hydrocarbon source, which includes or is a gas or vapor, into the chamber. The hydrocarbon source is at least partially thermally decomposed in the chamber to form carbon deposits, thereby coating the heated precipitated silica particles with the carbon deposits and forming carbon-coated precipitated silica particles.

[0087] Various details, examples, operating parameters, and other aspects of the method described above with respect to carbonaceous base particles as coated particles are equally applicable hereto to this part of the present invention.

[0088] In this invention, it has been discovered that the size of the base particles can affect the ability to achieve carbon-coated particles. The coated particles are in the form of fine particles, but can also be in the form of larger aggregates (especially from commercial sources supplying the particles). Therefore, one aspect of the invention may include the step of reducing the size of the particles to be coated, thereby resulting in carbon-coated particles of a certain size.

[0089] Alternatively, deaggregation can occur within the same chamber, through the same heating of particles that lead to the thermal decomposition of the hydrocarbon source.

[0090] With respect to the step of a method for deaggregating particles (such as rC aggregates), the method described in U.S. Patent Application No. 63 / 493,812, filed on April 3, 2023 (which is incorporated herein by reference in its entirety), can be utilized here prior to the step of coating the particles. In summary, a method for at least partially deaggregating particles such as carbon particles, e.g., rC aggregates, essentially consists of, comprises, or includes introducing particles such as rC aggregates (e.g., starting rC aggregates) into a heating chamber having one or more zones. As part of the method, the heating chamber has at least one zone having a zone temperature of at least 800°C or at least 900°C. The starting particles, e.g., rC aggregates, are in at least one zone having a zone temperature for a period of time sufficient to result in the deaggregation of at least a portion of the particles such as rC aggregates. Thus, the method results in obtaining deaggregated particles such as deaggregated rC aggregates (i.e., aggregates having a small aggregate size, or aggregates having a smaller aggregate size compared to the starting aggregate size of the starting rC aggregates). Other steps can be performed before and / or after deagglutination.

[0091] The aggregate size distribution can be measured using TEM images of the particles according to the ASTM D3849 method. Approximately 20 mg of particles were added to 13 mL of chloroform in a beaker and then sonicated for 10 minutes at 50% amplitude using a Misonix XL2020 with a half-inch tip sonication probe, surrounded by an ice bath. The sonicated dispersion was further diluted to approximately 100–120 ppm with additional chloroform and then sonicated again with the probe for a further 3 minutes. A drop of this dispersion was placed on a 200-mesh carbon-coated TEM grid and dried in a desiccator. TEM images were acquired using a JEOL JEM-1200 transmission electron microscope (TEM) with an electron acceleration voltage of 80 kV, an image resolution of 1.6 nm / pixel, and a field of view of at least 5 μm × 5 μm. The images can then be analyzed according to the ASTM D3849 method using an automated program based on the NIH ImageJ macro language and Microsoft Excel Visual Basic for Applications (VBA). The projected area equivalent diameter Dcircle of the recycled carbon aggregates was used as the measurement standard for aggregate size. At least 2000 aggregates were analyzed to obtain both the number-weighted aggregate size distribution and the volume-weighted aggregate size distribution of the recycled carbon samples.

[0092] The presence of rC aggregates larger than 1 micron is considered to be the main cause of the low rubber-reinforced properties when used as a partial or complete substitute for virgin carbon black. Aggregates larger than 1 micron can account for the majority of the total rC aggregates by mass. Therefore, a substantial proportion of the starting rC aggregates or other aggregates of similar size is considered to be detrimental to providing positive rubber-reinforced properties, or actually obtaining positive rubber-reinforced properties, when used "as is."

[0093] Furthermore, starting aggregates with aggregate sizes larger than 1 micron (e.g., 1.1 to 10 microns or more) are considered to substantially reduce fatigue life and wear resistance when used in compositions such as elastomer products. For example, elastomer products manufactured using starting rC aggregates may have 5 to 10 times more large non-dispersed particles compared to typical carbon black-containing elastomer composites that contain virgin carbon black instead of starting rC aggregates.

[0094] Large, undispersed rC particles or other particles can be a significant factor in reducing fatigue life in tire sidewall formulations containing rC compared to sidewall formulations containing virgin carbon black (e.g., up to a 60% reduction in fatigue life according to the Dematia fatigue test).

[0095] The drawings are provided to illustrate embodiments of the present invention in a simplified and schematic manner.

[0096] Figure 1 provides a schematic cross-sectional view of a configuration for an embodiment of the present invention. The entire system or device 10 may have at least one chamber 14 in which heating of particles (e.g., carbon particles 18) occurs. The particles are introduced through an inlet or entry or door 20, and when the process is complete, the carbon-coated particles can exit in the same way through the inlet 20 or through an outlet or door 22. The particles may be on a bed or other support surface 24. This may be a fixed bed or a moving bed. Hydrocarbon gas or vapor may be introduced into the chamber 14 via a pipe or injector or feed unit 12. If desired, more than one feed unit may be present and uniformly distributed across the chamber. An energy source 16 is located inside or adjacent to the chamber 14. The location of the energy source (or part thereof) may be below, above, or around the particles 18.

[0097] Once carbon-coated particles are formed, they can be recovered by exiting the chamber through the exit. For the recovery step, the carbon-coated particles may be cooled by one or more quenching steps, which may be in one or more quenching zones. The carbon-coated particles can be recovered in the same or similar manner as virgin carbon black is recovered from a carbon black reactor.

[0098] Figure 2 provides a simplified cross-sectional view of a further embodiment of the system or configuration 30 of the present invention in which two chambers are used. The first chamber 42 can initially receive particles 48 (e.g., carbon particles or other particles) and heating can be performed in the first chamber in the absence of a hydrocarbon source. Heating can be performed in an oxygen atmosphere, an inert atmosphere, or a vacuum. Heating of the particles in the first chamber can provide sufficiently heated particles so that when placed in contact with the hydrocarbon source (in the second chamber 34), the hydrocarbon source introduced through the tube or feed section 32 will be thermally decomposed and coat the particles 37, and / or heating can be used to deaggregate the particles 48. Heating of the first chamber can be achieved using any energy source 44 as described herein or other types of energy sources (e.g., an oven, a kiln, etc.). The location of the energy source (or part thereof) may be below, above, or around the particles 48. Once heating is achieved in the first chamber 42, the heated particles can be transferred by any conventional means (e.g., trays, conveyor belts, containers, feeders) to an inlet or entry or door 38 into the second or main chamber 34 46, and the heated particles 37 can be subjected to a hydrocarbon-containing gas or vapor which can be introduced into the chamber 34 via a tube or injector or feeder 32. After the particles have been coated, they can exit in the same way through the inlet 38 or through an outlet or door 50. The particles may be on a bed or other support surface 35, which may be a fixed or moving bed. If desired, more than one feeder may be present and uniformly distributed across the chamber. An energy source 36 is optionally located in or adjacent to the chamber 34. A further energy source 36 may be used to maintain the particles at a desired temperature and / or to remove volatile substances from the particles. The location of the energy source (or part thereof) may be below, above, or around the particles 37.

[0099] As an option, the base particles may be coated in a two-step process. For example, the particles 18 exiting the chamber 14 may be directed to a further chamber similar to either chamber 14 or chamber 34 and may be coated with additional carbon. The further chamber may be maintained at a temperature higher or lower than that of chamber 14. Alternatively or additionally, the particles 38 exiting the chamber 34 may be directed to a further chamber similar to either chamber 14 or chamber 34 and may be coated with additional carbon. The further chamber may be maintained at a temperature higher or lower than that of chamber 34. The use of a higher or lower temperature may affect one or more of the kinetics of carbon deposition and the proportion of amorphous and graphitic carbon. Without being bound by any particular theory, a higher temperature is thought to correlate with a lower specific I D / I G as described by, and may affect one or more of the kinetics of carbon deposition and the proportion of amorphous and graphitic carbon. Without being bound by any particular theory, a higher temperature is thought to correlate with a lower specific I D / I G and thus is thought to correlate with a higher proportion of graphitic carbon and / or a larger graphitic crystallite size La.

[0100] As an option, the starting base particles may be subjected to one or more size reduction processes, such as mechanical milling, before being introduced into the chamber. Mechanical milling can reduce the size of any weak aggregates to form starting carbon particles or other particles. However, mechanical milling does not reduce the aggregate size of particles such as rC. Generally, the mill can be configured to grind, mill, and / or finely crush the starting carbon particles or other particles into smaller weak aggregates. The mill can include a hammer mill, bead mill, jet mill, steam mill, and / or any other grinder, pulverizer, or milling machine. The grinding steps and / or techniques and the parameters of the starting and ground particles as described in International (PCT) Publication No. 2023 / 122582, filed Dec. 20, 2022, which is hereby incorporated by reference in its entirety, can be utilized here for the purposes of the present invention.

[0101] The mill can be directly coupled to the chamber inlet. For example, rC or other particles can be fed into the mill, which then directly feeds the ground rC or other particles into the chamber. Alternatively, the mill may be separate from the chamber in which particles such as rC are first ground and then transported to the chamber inlet.

[0102] After the carbon-coated particles are formed, the method of the present invention may include a quenching step.

[0103] As an option, the outlet of the chamber can lead to the inlet of a quenching chamber or quenching zone. The quenching chamber can spray a quenching fluid, such as water, onto the carbon-coated particles. Generally, quenching helps to cool the starting base particles. Optionally, quenching may be stepwise or performed at several points within the quenching chamber. Pressure spray, gas atomization spray, or other quenching techniques are available. With regard to completely quenching the carbon-coated particles or other particles, any conventional means for quenching the carbon-coated particles or other particles downstream of the chamber can be used and are known to those skilled in the art. For example, a quenching fluid, which may be water or other suitable fluid, can be injected to cool the carbon-coated particles or other particles.

[0104] After rapid cooling, the cooled carbon-coated particles or other particles are passed downstream to any conventional cooling and separation means, thereby recovering the carbon-coated particles. Any conventional means for recovering the coated particles can be used, including, but not limited to, sedimentation units, cyclone separators, bag filters, or other means known to those skilled in the art. After recovery, the carbon-coated particles may be subjected to a pelletizing step, as is optional, similar to virgin carbon black.

[0105] To pelletize carbon-coated particles in a mixer, a spray nozzle can moisten the carbon-coated particles or other particles with a binder such as water, toluene, or mineral oil. The mixer mixes the binder with the carbon-coated particles to form a substantially homogeneous mixture that weakly aggregates (or clumps) into pellets of carbon-coated particles. The pellets can then be dried to a specific moisture content, for example, less than 1% by weight. By reducing the moisture content of the pellets, the method of the present invention can prevent the introduction of undesirable moisture into the rubber mixture, which may contribute to gas emissions (or off-gas generation) released when the pellets are heated in a rubber mixer and / or plastic masterbatch mixer. These gas emissions may carry toxic components, such as polycyclic aromatic hydrocarbons, into the air of the production facility as residual moisture in the weak aggregates evaporates under heating.

[0106] The carbon-coated particles of the present invention can be used as a component in elastomers or rubber products, as a substitute for carbon black or other reinforcing agents, or in combination therewith. The carbon-coated particles can be used in materials, for example, as a reinforcing agent or filler in rubber products, for example, in tire components.

[0107] The carbon-coated particles of the present invention 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 airplane tires.

[0108] In other applications, the carbon-coated particles of the present invention 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, weatherstrip articles, bumpers, and vibration damping components.

[0109] The carbon-coated particles of the present invention can be added in place of or in addition to a first reinforcing agent for tire components and / or other industrial rubber end applications. The carbon-coated particles of the present invention can be combined 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.

[0110] The performance of the carbon-coated particles of the present invention as a reinforcing agent for rubber compounds can be evaluated, for example, by determining the performance of a rubber composition utilizing the carbon-coated particles of the present invention in comparison to the performance of a comparative rubber composition that is identical in all respects except for the use of the carbon-coated particles of the present invention. Alternatively, the values ​​obtained for compositions prepared according to the present invention can be compared to known values ​​in the art that are relevant to desired parameters in a given application.

[0111] Carbon-coated rC or other particles using the processes provided herein may improve the performance of rubber compounds prepared with carbon-coated materials compared to uncoated base particles. For example, carbon-coated rC may improve reinforcing properties such as tensile modulus, hysteresis (measured by tanδ), tear strength, and / or fatigue life. The performance of rubber compounds prepared with coated rC may be comparable to that of rubber compounds prepared with virgin carbon black. Alternatively or additionally, the performance of rubber compounds prepared with coated rC may be comparable to that of rubber compounds prepared with uncoated rC. In any of these embodiments, performance may be determined by one or more of the following: tensile modulus at 100% strain, tensile modulus at 300% strain, elongation at break, tanδ (60°C), tear strength (ASTM D624, Die B), and / or fatigue life (ASTM D4482). For any of these properties, performance may be improved by at least 5%, at least 10%, at least 15%, or at least 20%, for example, 5–25%, 10–20%, 5–15%, or 15–30%. Tensile modulus and elongation at break are measured according to ASTM D412 (Test Method A, Type C) at 23°C, 50% relative humidity, and a crosshead speed of 500 mm / min. tanδ60 o This is determined using a dynamic strain sweep of 0.01% to 60% at 10 Hz and 60°C. tanδ max (Sometimes written as tanδ) is taken as the maximum value of tanδ within the strain in this range. Fatigue life is measured according to ASTM D4482.

[0112] Unless otherwise specified, all material percentages expressed herein as percentages are weight percentages.

[0113] The present invention includes the following aspects / embodiments / features in any order and / or any combination. 1. The present invention includes a method for forming carbon-coated base particles, for example, carbon-coated carbon particles, the method being: A method comprising: introducing base particles into a chamber; subjecting the base particles to an energy source which is at least one of a high-temperature gas, microwave energy, induction energy, direct current passing through the base particles, electromagnetic radiation, or solar radiation to form heated base particles; and supplying a hydrocarbon source which includes gas or vapor to the chamber, wherein the hydrocarbon source at least partially thermally decomposes in the chamber to form carbon deposits, thereby coating the heated base particles with the carbon deposits to form carbon-coated base particles, wherein the base particles optionally include recycled carbon particles. 2. Any embodiment / feature / appearance of the above or below, wherein the base particles include carbon particles or particles having a carbon content of at least 10% or at least 75%. 3. Any embodiment / feature / method described above or below, wherein the base particles include solid hydrothermal carbon (HTC), carbon particles which are non-ASTM reinforced grade particles, silicon-treated carbon black, silica-coated carbon black, graphene, reduced graphene oxide, single-walled carbon nanotubes, multi-walled carbon nanotubes, carbon nanostructures, carbon black coated particles, biochar, and carbon particles which are any combination thereof. 4. Any embodiment / feature / appearance of the above or below, wherein the base particles include graphene oxide, lignin, or nanocrystalline cellulose, bio-based particles, polysaccharides, artificial polysaccharides, or any combination thereof. 5. A method according to any of the above or below embodiments / features / appearances, wherein the recycled carbon particles include deaggregated and / or pulverized recycled carbon particles. 6. Any method of the above or below embodiment / features / appearances wherein the base particles include precipitated silica, rice husk silica, clay, nanoclay, diatomaceous earth, metal oxides, metal carbonates, or any combination thereof. 7. A method according to any of the above or below embodiments / features / aspects, wherein the base particles are subjected to microwave energy. 8. Any method according to the above or below embodiment / features / appearances, wherein the microwave energy is at least 0.5 GHz, for example, 0.5 GHz to 10 GHz. 9. A method according to any of the above or below embodiments / features / aspects, wherein the base particle is supplied with induction energy. 10. Any above or below embodiment / feature / method of which the induced energy is provided by an induction heater operating at a frequency of at least 5 kHz. 11. Any above or below embodiment / feature / method of which the induced energy is provided by an induction heater operating at a frequency of 5 kHz to 500 kHz. 12. Any above or below embodiment / feature / method of which the induction heater operates with an induction heater power of at least 50 MJ / kg. 13. Any above or below embodiment / feature / method of which the induction heater operates with an induction heater power of 50 MJ / kg to 250 MJ / kg. 14. Any above or below embodiment / feature / aspect of a method, in which the chamber includes a fluidized bed reactor, an ablative pyrolysis reactor, a vacuum pyrolysis reactor, a fixed-bed fall reactor, or a solar pyrolyzer. 15. Any embodiment / feature / appearance described above or below, wherein microwave energy or induced energy is generated from renewable electricity. 16. Any embodiment / feature / appearance of the above or below, wherein the base particles are bio-based particles. 17. Any above or below embodiment / feature / appearance of a method in which the hydrocarbon source includes natural gas. 18. Any above or below embodiment / feature / appearance of a method wherein the hydrocarbon source consists of natural gas. 19. Any method of the above or below embodiment / feature / aspect carried out in the absence of a catalyst. 20. Any of the above or below embodiments / features / aspects of a method carried out in the absence of introduced oxygen. 21. Any embodiment / feature / appearance described above or below, wherein the method yields a maximum of 0.5 kg of carbon dioxide and carbon monoxide per 1 kg of carbon-coated particles, for example, a method that does not produce any carbon dioxide or carbon monoxide at all. 22. Any method according to the above or below embodiment / feature / appearance, wherein the base particles are heated to a temperature of at least 800°C. 23. Any method according to the above or below embodiment / feature / appearance, wherein the base particles are heated to a temperature of at least 900°C. 24. Any method according to the above or below embodiments / features / aspects, wherein the base particles are heated to a temperature of at least 1000°C. 25. Any method according to the above or below embodiment / feature / appearance, wherein the base particles are heated to a temperature of at least 1500°C. 26. Any embodiment / features / aspects of the above or below, wherein the hydrocarbon source includes bio-oil, recycled oil, sustainable oil vapor; biofuel or by-product of biochemical production, or tires, e.g., oil derived from tire pyrolysis, oil derived from plastic pyrolysis or recycling, or oil derived from hydrothermal liquefaction or paper processing. 27. A method according to any of the above or below embodiments / features / aspects, wherein the base particles are on a fixed bed in a chamber. 28. A method of any of the above or below embodiments / features / aspects, wherein the base particles are on a moving bed through a chamber. 29. Any embodiment / feature / approach described above or below, wherein carbon deposits uniformly coat base particles. 30. Any above or below embodiment / feature / appearance of a method in which carbon deposits at least partially cover base particles. 31. A method according to any of the above or below embodiments / features / appearances, wherein the product carbon-coated base particles have a coating having an average thickness of 0.5 to 500 nanometers. 32. A method according to any of the above or below embodiments / features / appearances, wherein the base particles have a residence time of 1 second to 3 hours in the chamber. 33. A method according to any of the above or below embodiments / features / appearances, wherein the base particles have a residence time of 5 seconds to 2 hours in the chamber. 34. Any embodiment / feature / mode of the above or below, wherein the chamber comprises at least a first chamber and a second chamber, and in the first chamber, the base particles are subjected to microwave energy or inductive energy so that the base particles reach an average surface temperature of at least 800°C in the complete absence of a hydrocarbon source to obtain heated base particles, and the heated base particles are then transported to the second chamber where the hydrocarbon source is supplied. 35. A method according to any of the above or below embodiments / features / aspects, wherein the second chamber has a heating source that maintains the heated base particles at a surface temperature of at least 800°C. 36. A method of any of the above or below embodiments / features / aspects, wherein heated base particles are on a moving bed in a second chamber. 37. Any embodiment / feature / approach described above or below, of which recycled iron or limestone is applied to at least a portion of the surface of the base particles before being used as the energy source. 38. Any above or below embodiment / feature / aspect of a method in which base particles are at least partially deaggregated within the first chamber. 39. Any embodiment / feature / aspect of the method described above or below, wherein an oxidizing atmosphere is present in the chamber for at least part of the method. 40. Any of the above or below embodiments / features / aspects of the method, wherein an oxidizing atmosphere is present in the chamber for at least a portion of the method achieved by introducing water into the chamber. 41. Any embodiment / feature / approach described above or below, further comprising performing steam oxidation of base particles within the chamber. 42. Any embodiment / feature / appearance of the above or below, further comprising heating the carbon-coated particles in a neutral or reducing atmosphere in either the same chamber or a different chamber in the second step. 43. Any method according to any of the above or below embodiments / features / aspects, wherein a nonreactive carrier gas is present together with a hydrocarbon source. 44. Any embodiment / feature / approach described above or below, wherein a hydrocarbon gas is introduced into the chamber at two or more locations within the chamber. 45. Any embodiment / feature / approach described above or below, wherein a non-reactive carrier gas is introduced into the chamber at two or more locations within the chamber, either separately or together with the hydrocarbon gas. 46. ​​A method of any above or below embodiment / feature / appearance in which the first chamber has a volume at least 25% smaller than the volume of the second chamber. 47. Any above or below embodiment / feature / appearance of the method wherein the first chamber has a volume at least 50% smaller than the volume of the second chamber. 48. Any embodiment / feature / model of the above or below, further comprising: introducing carbon-coated base particles into an additional chamber; subjecting the base particles to an energy source which is at least one of a high-temperature gas, microwave energy, induced energy, direct current passing through the base particles, electromagnetic radiation, or solar radiation to form heated carbon-coated base particles; and supplying a hydrocarbon source which includes gas or vapor to the additional chamber, wherein the hydrocarbon source is at least partially thermally decomposed in the additional chamber to form carbon deposits, thereby coating the heated carbon-coated base particles with additional carbon deposits. 49. The present invention further relates to a method for forming carbon-coated precipitated silica particles, the method comprising: introducing precipitated silica particles into a chamber; subjecting the precipitated silica particles to microwave energy or induced energy to form heated precipitated silica particles; and supplying a hydrocarbon source containing gas or vapor to the chamber, wherein the hydrocarbon source at least partially thermally decomposes in the chamber to form carbon deposits, thereby coating the heated precipitated silica particles with the carbon deposits to form the carbon-coated precipitated silica particles. 50. The present invention further relates to coated carbon particles or other particles formed by any of the above or below embodiments / features / aspects. 51. The present invention further relates to a method for producing hydrogen, comprising carrying out any of the above or below embodiments / features / aspects, wherein the thermal decomposition of a hydrocarbon source results in the production of a hydrogen-containing gaseous stream. 52. Any above or below embodiment / feature / model of a method further comprising separating hydrogen from the rest of the gas stream in order to obtain a purified hydrogen stream. 53. Any above or below embodiment / feature / appearance of the method, further comprising a hydrocarbon source for the remainder of the gas flow. 54. Any above or below embodiment / feature / model of the method wherein the gas stream contains at least 60 volume percent of hydrogen, for example, 80 to 99 volume percent of hydrogen. 55. The present invention further relates to carbon-coated particles, each comprising a base particle and a carbon deposit arranged around the outer surface of the base particle, wherein the carbon-coated particles have a Raman D band of 0.5 to 2.45, for example, 1 to 2.45 or 1.5 to 2.45 (1340 cm²). -1 ) and Raman G band (1590cm) -1 This relates to carbon-coated particles having the ratio of the areas of ). 56. Carbon-coated particles of any of the above or below embodiments / features / models, wherein the base particles include carbon particles or particles having a carbon content of at least 10% by weight or at least 75% by weight. 57. Carbon-coated particles of any of the above or below embodiments / features / models, wherein the base particles include recycled carbon particles. 58. Carbon-coated particles of any of the above or below embodiments / features / models, wherein the base particles include carbon particles which are non-ASTM reinforced grade particles, solid hydrothermal carbon (HTC), silicon-treated carbon black, silica-coated carbon black, graphene, reduced graphene oxide, single-walled carbon nanotubes, multi-walled carbon nanotubes, carbon nanostructures, carbon black-coated particles, biochar, and any combination thereof. 59. Carbon-coated particles of any of the above or below embodiments / features / models, wherein the base particles include graphene oxide, lignin, nanocrystalline cellulose, bio-based particles, polysaccharides, artificial polysaccharides, or any combination thereof. 60. Carbon-coated particles of any of the above or below embodiments / features / models, comprising recycled carbon particles that have been deaggregated and / or pulverized. 61. Carbon-coated particles of any of the above or below embodiments / features / models, wherein the base particles include precipitated silica, rice husk silica, clay, nanoclay, diatomaceous earth, metal oxides, metal carbonates, or any combination thereof. 62. Carbon-coated particles of any of the above or below embodiments / features / models, wherein the carbon deposit coating has an average thickness of 0.5 nm to 500 nm. 63. Rubber articles incorporating carbon-coated particles of any of the above or below embodiments / features / appearances. 64. Any rubber article of the above or below embodiment / features / models, wherein the rubber article is a tire component selected from the group consisting of tire treads, sub-treads, wire skims, sidewalls, and cushion gums, engine mounts, hydro mounts, bridge bearings, seismic isolation devices, tank trucks, tank treads, mining belts, hoses, gaskets, seals, blades, weatherstrip articles, bumpers, or vibration damping components. 65. The present invention further relates to an elastomer composite material comprising carbon-coated particles of any of the above or below embodiments / features / aspects, wherein the base particles are recycled carbon, and the elastomer composite material has at least one mechanical property selected from tensile modulus at 100% strain, tensile modulus at 300% strain, elongation at break, tanδ at 60°C, tear strength, and fatigue life, and the magnitude of the mechanical property is at least 5% greater than that of an elastomer composite material having the same composition but with recycled carbon instead of carbon-coated particles. [Examples]

[0114] Example 1 - Recycled carbon (CBP Cyprus Ltd) was supplied to a tubular furnace at a rate of 360 g / hr and processed at the temperatures specified in Table 1 below for a residence time of approximately 1 hour. The tube was 6 inches (15 cm) in diameter and 60 inches (152 cm) long at the heating section, and rotated at a speed of 1.8 rpm. Gas was supplied to the tube at a rate of 25 scfh (708 L / h) (nitrogen) or 21 scfh (595 L / h) (methane), and the system inlet and outlet were purged using an additional 6 scfh (170 L / h) of nitrogen at all times. After 1 hour of steady-state operation, a sample was collected, which meant that the flow of rC into and out of the furnace was stable, the temperature was stable, and the desired gas (nitrogen or methane) had been flowing through the tube for at least 90 minutes. [Table 1] *Percentage increase in carbon calculated based on a constant silicon standard

[0115] Elemental analysis was first determined by determining the mass percentage of carbon, assuming that all non-ash content was carbon, using the ashing method specified in ASTM D1506. Inorganic elements were quantified by scanning electron microscopy / energy-dispersive X-ray spectroscopy (SEM / EDS) of a thick layer of ash stamped onto a SEM stub with carbon tape. A 560 micron × 420 micron area was scanned with the EDS detector until a total of 50,000,000 X-ray counts were recorded.

[0116] The results demonstrate that carbon was deposited on the surface of the rC particles. The decrease in ash also suggests that ZnO in the rC was reduced, followed by the evaporation of metallic zinc (boiling point 907°C). Assuming little to no silicon loss during deposition, the increase in Si concentration in the ash suggests a decrease in the amount of ash, while the decrease in the proportion of Si in the rC suggests the addition of new carbon to the rC, which increases with the processing temperature. D / I G The decrease indicates that the crystallinity of the deposited carbon is increasing with increasing treatment temperature.

[0117] Example 2 - Recycled carbon (e.g., from CBP Cyprus Ltd) is coated with carbon in a pilot-scale fluidized bed reactor system substantially similar to that considered with respect to Figure 2 of U.S. Patent No. 1,0087330, the entirety of which is incorporated herein by reference. The ideal fluidization rate of the recycled carbon is evaluated using air at room temperature in a bench-scale fluidization device. The initial input of recycled carbon starting material is placed in the fluidized bed so as to be positioned above the bottom plate. The bed is then sealed, and a nitrogen stream is passed through the recycled carbon, through the bottom plenum, through the bottom plate, then through the recycled carbon, and finally out through the top of the fluidized bed reactor. An electric heater is activated to raise the bed temperature to 1000°C. The nitrogen stream is then stopped, and a natural gas stream with an empty column velocity approximately equal to the ideal fluidization rate is introduced, and operation is started. Samples are periodically drawn from the bed using immersion tubes and measured to track the progress of carbon black deposition. At the end of the desired operating time, the natural gas flow is switched off along with the electric heater, and nitrogen is passed back through the fluidized bed, while it is being cooled to room temperature. The final bed product is then collected from the bottom of the fluidized bed reactor. This product is expected to have carbon deposited on the surface and a reduced amount of zinc compared to the starting product.

[0118] Example 3 - Particulate silica (e.g., precipitated silica) is coated with carbon in a pilot-scale fluidized bed reactor having a configuration similar to that considered with respect to Figure 2 of U.S. Patent No. 1,0087330, the entire content of which is incorporated herein by reference. The ideal fluidization rate of the particulate silica is evaluated using air at room temperature in a bench-scale fluidization device. The initial input of the particulate silica starting material is placed in the fluidized bed so that it is positioned above the bottom plate. The bed is then sealed and a nitrogen stream is introduced through the particulate silica, through the bottom plenum, through the bottom plate, then through the particulate silica, and finally out through the top of the fluidized bed reactor. An electric heater is activated to raise the bed temperature to 1250°C. The nitrogen stream is then stopped and a natural gas stream with an empty velocity approximately equal to the ideal fluidization rate is introduced and operation is started. Samples are periodically drawn from the bed using immersion tubes and measured to track the progress of carbon black deposition. At the end of the desired operating time, the natural gas flow is switched off along with the electric heater, and nitrogen is passed back through the fluidized bed, while it cools to room temperature. The final bed product is then collected from the bottom of the fluidized bed reactor. This product is expected to have carbon deposits on its surface.

[0119] Example 4. Using each of the five particles from Example 1, the amounts of flecks and curing agent shown in Table 2, and Kralex SBR 1502 styrene-butadiene rubber (Synthos), an elastomer composite material with a particle fill weight of 50 phr was prepared. All compositions were mixed in two steps in a 439 mL Brabender Prep-mixer with two cam rotors, as described in Table 3. The compound was sheeted on a two-roll mill operated at 50°C and approximately 22 rpm, followed by six passes through a nip gap of approximately 5 mm, with a resting time of at least 3 hours before the next mixing stage (or curing after the final stage). Curing was carried out in a heated press (150°C, 2500 lbs) for 30 minutes. Compounds prepared using carbon-coated rC are expected to exhibit superior mechanical properties (e.g., an improvement of at least 5% in one or more of the following: tensile modulus at 100% strain, tensile modulus at 300% strain, elongation at fracture, tanδ (60°C), tear strength, and fatigue life) compared to compounds prepared using uncoated rC. [Table 2] a) N-(1,3-dimethylbutyl)-N'-phenyl-p-phenylenediamine, 6PPD (Western Reserve Chemical) b) Poly(1,2-dihydro-2,2,4-trimethylquinoline), antioxidant DQ pellets (Akrochem Corporation) c) Manufactured by Akrochem Corporation d) AKROWAX (trademark) 5031 (Akrochem Corporation) e) N-tert-butyl-2-benzothiazole sulfenamide (Akrochem Corporation) [Table 3]

[0120] 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.

[0121] 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 as specifically disclosing 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 specified, the range is intended to include its endpoints, as well as all integers and fractions within that range. The range of the present invention is not intended to be limited to any specific values ​​enumerated when defining a range.

[0122] 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 forming carbon-coated base particles, A method comprising: introducing base particles into a chamber; subjecting the base particles to an energy source which is at least one of a high-temperature gas, microwave energy, induction energy, direct current passing through the base particles, electromagnetic radiation, or solar radiation to form heated base particles; and supplying a hydrocarbon source which includes gas or vapor to the chamber, wherein the hydrocarbon source is at least partially thermally decomposed in the chamber to form carbon deposits, thereby coating the heated base particles with the carbon deposits to form carbon-coated base particles, wherein the base particles optionally include recycled carbon particles.

2. The method according to claim 1, wherein the base particles include carbon particles or particles having a carbon content of at least 10% or at least 75%.

3. The method according to claim 1 or 2, wherein the base particles include carbon particles which are non-ASTM reinforced grade particles, solid hydrothermal carbon (HTC), silicon-treated carbon black, silica-coated carbon black, graphene, reduced graphene oxide, single-walled carbon nanotubes, multi-walled carbon nanotubes, carbon nanostructures, carbon black coated particles, biochar, and any combination thereof.

4. The method according to any one of claims 1 to 3, wherein the base particles include graphene oxide, lignin, nanocrystalline cellulose, bio-based particles, polysaccharides, artificial polysaccharides, or any combination thereof.

5. The method according to any one of claims 1 to 4, wherein the recycled carbon particles include deaggregated and / or pulverized recycled carbon particles.

6. The method according to any one of claims 1 to 5, wherein the base particles include precipitated silica, rice husk silica, clay, nanoclay, diatomaceous earth, metal oxides, metal carbonates, or any combination thereof.

7. The method according to any one of claims 1 to 6, wherein the base particles are subjected to the microwave energy.

8. The method according to claim 7, wherein the microwave energy is at least 0.5 GHz, for example, 0.5 GHz to 10 GHz.

9. The method according to any one of claims 1 to 6, wherein the base particles are subjected to the induction energy.

10. The method according to claim 9, wherein the induced energy is provided by an induction heater operating at a frequency of at least 5 kHz.

11. The method according to claim 9 or 10, wherein the induced energy is provided by an induction heater operating at a frequency of 5 kHz to 500 kHz.

12. The method according to any one of claims 9 to 11, wherein the induction heater operates with an induction heater power of at least 50 MJ / kg.

13. The method according to any one of claims 9 to 12, wherein the induction heater operates with an induction heater power of 50 MJ / kg to 250 MJ / kg.

14. The method according to any one of claims 1 to 13, wherein the chamber includes a fluidized bed reactor, an ablative pyrolysis reactor, a vacuum pyrolysis reactor, a fixed-bed fall reactor, or a solar pyrolyzer.

15. The method according to any one of claims 1 to 14, wherein the microwave energy or induced energy is generated from renewable electricity.

16. The method according to any one of claims 1 to 15, wherein the base particles are bio-based particles.

17. The method according to any one of claims 1 to 16, wherein the hydrocarbon source includes natural gas.

18. The method according to any one of claims 1 to 17, wherein the hydrocarbon source is natural gas.

19. The method according to any one of claims 1 to 18, carried out in the absence of a catalyst.

20. The method according to any one of claims 1 to 19, carried out in the absence of introduced oxygen.

21. The method according to any one of claims 1 to 20, which yields up to 0.5 kg of carbon dioxide and carbon monoxide per 1 kg of carbon-coated particles.

22. The method according to any one of claims 1 to 21, wherein the base particles are heated to a temperature of at least 800°C.

23. The method according to any one of claims 1 to 22, wherein the base particles are heated to a temperature of at least 900°C.

24. The method according to any one of claims 1 to 23, wherein the base particles are heated to a temperature of at least 1000°C.

25. The method according to any one of claims 1 to 24, wherein the base particles are heated to a temperature of at least 1500°C.

26. The method according to any one of claims 1 to 25, wherein the hydrocarbon source includes bio-oil, recycled oil, sustainable oil vapor; biofuel or by-product of biochemical production, or oil derived from tires, tire pyrolysis oil, oil derived from plastic pyrolysis or recycling, or oil derived from hydrothermal liquefaction or paper processing.

27. The method according to any one of claims 1 to 26, wherein the base particles are located on a fixed bed within the chamber.

28. The method according to any one of claims 1 to 27, wherein the base particles are on a moving bed through which the chamber passes.

29. The method according to any one of claims 1 to 28, wherein the carbon deposit uniformly coats the base particles.

30. The method according to any one of claims 1 to 29, wherein the carbon deposit at least partially covers the base particles.

31. The method according to any one of claims 1 to 30, wherein the product carbon-coated particles have a coating having an average thickness of 0.5 to 500 nanometers.

32. The method according to any one of claims 1 to 31, wherein the base particles have a residence time of 1 second to 3 hours in the chamber.

33. The method according to any one of claims 1 to 32, wherein the base particles have a residence time of 5 seconds to 2 hours in the chamber.

34. The method according to any one of claims 1 to 33, wherein the chamber comprises at least a first chamber and a second chamber, and in the first chamber, the base particles are subjected to microwave energy or inductive energy such that the base particles reach an average surface temperature of at least 800°C in the complete absence of a hydrocarbon source to obtain heated base particles, and then the heated base particles are transported to the second chamber through which the hydrocarbon source is supplied.

35. The method according to claim 34, wherein the second chamber has a heating source for maintaining the heated base particles at a surface temperature of at least 800°C.

36. The method according to claim 34 or 35, wherein the heated base particles are located on a moving floor in the second chamber.

37. The method according to any one of claims 34 to 36, wherein the base particles are at least partially deaggregated in the first chamber.

38. The method according to any one of claims 34 to 37, wherein the first chamber has a volume at least 25% smaller than the volume of the second chamber.

39. The method according to any one of claims 34 to 38, wherein the first chamber has a volume at least 50% smaller than the volume of the second chamber.

40. The method according to any one of claims 1 to 39, wherein recycled iron or limestone is applied to at least a portion of the surface of the base particles before being used as the energy source.

41. The method according to any one of claims 1 to 40, wherein an oxidizing atmosphere is present in the chamber for at least part of the method.

42. The method according to any one of claims 1 to 41, wherein an oxidizing atmosphere is present in the chamber for at least a portion of the method achieved by introducing water into the chamber.

43. The method according to any one of claims 1 to 42, further comprising performing steam oxidation of the base particles in the chamber.

44. The method according to any one of claims 1 to 43, further comprising, in the second step, heating the carbon-coated particles in a neutral atmosphere or a reducing atmosphere in either the same chamber or a different chamber.

45. The method according to any one of claims 1 to 44, wherein a non-reactive carrier gas is present together with the hydrocarbon source.

46. The method according to claim 45, wherein the nonreactive carrier gas is introduced into the chamber at two or more locations within the chamber, either separately or together with the hydrocarbon gas.

47. The method according to any one of claims 1 to 46, wherein the hydrocarbon gas is introduced into the chamber at two or more locations within the chamber.

48. The method according to any one of claims 1 to 47, further comprising: introducing the carbon-coated base particles into an additional chamber; subjecting the base particles to an energy source which is at least one of a high-temperature gas, microwave energy, induction energy, direct current passing through the base particles, electromagnetic radiation, or solar radiation to form heated carbon-coated base particles; and supplying a hydrocarbon source which includes gas or vapor to the additional chamber, wherein the hydrocarbon source is at least partially thermally decomposed in the additional chamber to form carbon deposits, thereby coating the heated carbon-coated base particles with additional carbon deposits.

49. A method for forming carbon-coated precipitated silica particles, A method comprising: introducing precipitated silica particles into a chamber; subjecting the precipitated silica particles to microwave energy or induction energy to form heated precipitated silica particles; and supplying a hydrocarbon source containing gas or vapor to the chamber, wherein the hydrocarbon source at least partially thermally decomposes in the chamber to form carbon deposits, thereby coating the heated precipitated silica particles with the carbon deposits to form carbon-coated precipitated silica particles.

50. A method for producing hydrogen, comprising carrying out the method according to any one of claims 1 to 49, wherein the thermal decomposition of the hydrocarbon source results in the production of a hydrogen-containing gaseous flow.

51. The method according to claim 50, further comprising separating hydrogen from the remaining portion of the gas stream in order to obtain a purified hydrogen stream.

52. The method according to claim 51, further comprising directing the remaining portion of the gas flow toward the hydrocarbon source.

53. The method according to any one of claims 50 to 52, wherein the gas flow contains at least 60 volume percent of hydrogen, for example, 80 to 99 volume percent of hydrogen.

54. Carbon-coated particles, each comprising a base particle and a carbon deposit arranged around the outer surface of the base particle, wherein the carbon-coated particles have a Raman D band of 0.5 to 2.45, for example, 1 to 2.45 or 1.5 to 2.45 (1340 cm⁻¹). －１ ) and Raman G band (1590 cm) －１ Carbon-coated particles having the area ratio of ).

55. The carbon-coated particles according to claim 54, wherein the base particles include carbon particles or particles having a carbon content of at least 10% by weight or at least 75% by weight.

56. The carbon-coated particles according to claim 54 or 55, wherein the base particles include recycled carbon particles.

57. The carbon-coated particles according to any one of claims 54 to 56, wherein the base particles include non-ASTM reinforced grade particles, solid hydrothermal carbon (HTC), silicon-treated carbon black, silica-coated carbon black, graphene, reduced graphene oxide, single-walled carbon nanotubes, multi-walled carbon nanotubes, carbon nanostructures, carbon black coated particles, biochar, and carbon particles which are any combination thereof.

58. The carbon-coated particles according to any one of claims 54 to 57, wherein the base particles include graphene oxide, lignin, nanocrystalline cellulose, bio-based particles, polysaccharides, artificial polysaccharides, or any combination thereof.

59. The carbon-coated particles according to any one of claims 54 to 58, wherein the recycled carbon particles include deaggregated and / or pulverized recycled carbon particles.

60. The carbon-coated particles according to any one of claims 54 to 59, wherein the base particles include precipitated silica, rice husk silica, clay, nanoclay, diatomaceous earth, metal oxides, metal carbonates, or any combination thereof.

61. The carbon-coated particle according to any one of claims 54 to 60, wherein the carbon deposit coating has an average thickness of 0.5 nm to 500 nm.

62. A rubber article incorporating carbon-coated particles according to any one of claims 54 to 61.

63. The rubber article according to claim 62, wherein the rubber article is a tire component selected from the group consisting of tire treads, sub-treads, wire skims, sidewalls, and cushion gums, engine mounts, hydro mounts, bridge bearings, seismic isolation devices, tank trucks, tank treads, mining belts, hoses, gaskets, seals, blades, weatherstrip articles, bumpers, or vibration damping parts.

64. An elastomer composite material comprising carbon-coated particles according to any one of claims 54 to 61, wherein the base particles are recycled carbon, and the elastomer composite material has at least one mechanical property selected from tensile modulus at 100% strain, tensile modulus at 300% strain, elongation at break, tanδ at 60°C, tear strength, and fatigue life, and the magnitude of the mechanical property is at least 5% greater than that of an elastomer composite material having the same composition but with recycled carbon instead of carbon-coated particles.

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