A method for producing carbon black from low-yield raw materials using a plasma or electric heating process, and a product produced therefrom.

Abstract

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

Description

[Technical Field]

[0001] The present invention relates to a method for producing carbon black produced from alternative carbon black production raw materials, which may often include gaseous and / or low-yield raw materials. More specifically, the present invention relates to a method for producing carbon black utilizing a plasma or electric heating process. The present invention further relates to carbon black formed from alternative carbon black production raw materials, which may include gaseous and / or low-yield carbon black raw materials.

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

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

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

[0005] Electrically driven processes can use renewable electricity instead of fossil fuel combustion, resulting in a substantial reduction in greenhouse gas emissions compared to furnace processes. Electrically driven processes offer higher carbon black yields per unit of raw material consumed and lower operating costs compared to furnace processes. The use of electrical energy to supply much or all of the energy required to drive pyrolysis allows for greater control over the gas-phase chemical environment formed by the carbon black. Because the energy does not need to be entirely derived from combustion, the chemical environment during particle formation can be more reductive (as opposed to oxidative). This provides further methods for controlling the final surface chemistry of the particles.

[0006] Electric heating carbon black processes tend to use natural gas, ethane, or similar gaseous carbon-containing raw materials as raw materials for carbon black production, as described, for example, in U.S. Patent No. 10100200. A drawback of these gaseous raw materials is that they tend to produce very little structure relative to a given surface area. This structure can often be too low to meet ASTM-grade requirements for rubber reinforcement.

[0007] A further drawback of the electrically heated carbon black process is the use of a carrier gas. This is done because directly exposing the carbon-containing raw material to high-temperature, intensely heated surfaces, such as those generated at electrodes, can lead to rapid coke formation and serious handling problems. Furthermore, many electrode materials can be corroded during use by high-temperature hydrocarbon gases.

[0008] The use of carrier gases such as hydrogen or argon solves these two problems, but it introduces another problem: the volume of the carrier gas must be large relative to the volume of the raw materials. Since high temperatures are required to generate a suitable surface area in aerosol-based carbon black processes, this means that as the required product surface area increases, increasingly larger amounts of carrier gas must be used relative to the amount of raw materials. This increase in carrier gas volume significantly increases capital costs.

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

[0010] Unfortunately, these low-yield carbon black raw materials generally result in lower yield, lower surface area, and / or lower structure in carbon black processes compared to conventionally used carbon black raw materials. The performance of these raw materials in electroheated carbon black processes may be so poor that it may be impossible to produce the structure required for most ASTM grades using them. The maximum structure achievable at a given surface area for a raw material helps define its grade capability.

[0011] Therefore, there is a need in this industry to provide a solution that can utilize an electroheated carbon black process, which can significantly increase the structure of the carbon black produced.

[0012] Furthermore, there is a need in this industry to provide solutions for reducing capital costs by achieving a given surface area at lower reaction temperatures for the electroheated carbon black process.

[0013] Furthermore, there is a need in the industry to provide a solution that allows for the use of various amounts of low-yield carbon black forming raw materials in existing electroheated carbon black processes, and that can produce carbon black comparable to that formed from conventional carbon black raw materials (e.g., producing carbon black with acceptable yield and / or high surface area and / or high structure). Using electroheated carbon black processes with these low-yield raw materials, instead of developing, designing, and building new processes to use them, saves significant capital and development resources. All patents and publications mentioned throughout this document are incorporated herein by reference in their entirety. [Overview of the project]

[0014] The feature of the present invention is to provide a method for preparing or producing carbon black from raw materials that include low-yield carbon black raw materials (or multiple low-yield raw materials).

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

[0016] Another feature of the present invention is to provide a method for preparing or producing carbon black using an electrically heated carbon black process, which significantly increases the structural integrity of the carbon black produced.

[0017] Moreover, a feature of the present invention is to provide a method for preparing or manufacturing carbon black using an electrically heated carbon black process, and by achieving a given surface area at a lower reaction temperature in the electrically heated carbon black process, the capital cost is reduced.

[0018] A further feature of the present invention is to provide carbon black produced from a raw material containing a low-yield carbon black raw material.

[0019] Another feature of the present invention is to provide carbon black produced from a raw material containing a gaseous carbon black raw material.

[0020] A further feature is to provide a method of using a carbon black raw material, wherein at least a part or more of the total amount of the raw material is a low-yield carbon black raw material.

[0021] [[ID=十六]]A further feature is to provide a method for manufacturing carbon black from a low-yield carbon black raw material such that the resulting carbon black has an acceptable (e.g., good) yield, an acceptable (e.g., high) surface area, and / or an acceptable structure (e.g., high structure).

[0022] It should be noted that in the translation of line , there is a small error in the original text numbering. It should be instead of [[ID=十六]]. The above translation has been corrected accordingly.To achieve these and other advantages, and in accordance with the objectives of the present invention, the present invention relates in part to a method for producing carbon black, as embodied and broadly described herein. Such a method includes the step of electrically heating a carrier gas and / or carbon black raw materials to cause thermal decomposition of at least a portion of the carbon black raw materials. The carbon black raw materials include at least one first carbon black raw material and at least one low-yield carbon black raw material. In one method of the present invention, the first carbon black raw material is first brought into contact with a heated carrier gas formed by electrically heating a carrier gas to form a reaction flow, and then the low-yield carbon black raw material is combined downstream with the existing reaction flow to form carbon black. The method further includes recovering the carbon black in the reaction flow. In the method, the at least one low-yield carbon black raw material preferably constitutes at least 10% by weight of the total raw materials and 90% by weight or less of the total raw materials (based on total weight).

[0023] Furthermore, the present invention relates in part to a further method for producing carbon black. Such a method includes the step of electrically heating a carrier gas and / or carbon black raw materials to cause thermal decomposition of at least a portion of the carbon black raw materials. The carbon black raw materials include at least one first carbon black raw material and at least one low-yield carbon black raw material. In this process of the present invention, the first carbon black raw material and the low-yield carbon black raw material are brought into contact with a heated carrier gas formed by electrically heating a carrier gas to form a reaction flow and to form carbon black. The at least one first carbon black raw material and the at least one low-yield carbon black raw material may be in the form of a blend or may be introduced separately at the same or substantially the same location. The method further includes recovering the carbon black in the reaction flow. In this method, the at least one low-yield carbon black raw material preferably constitutes at least 10% by weight of the total raw materials and 90% by weight or less of the total raw materials (based on total weight).

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

[0025] The present invention further relates to products and / or articles, such as elastomer composites, formed from one or more of the carbon blacks of the present invention, but is not limited thereto.

[0026] Please understand that both the general description above and the detailed description below are merely illustrative and descriptive, and further illustrate the scope of the claimed invention.

[0027] The accompanying drawings incorporated herein and constituting part of this specification illustrate various features of the present invention and, together with the detailed description, serve to illustrate the principles of the present invention. [Brief explanation of the drawing]

[0028] [Figure 1] This graph shows the atomic H:C (hydrogen atom to carbon atom) ratio of conventional carbon black raw materials compared to low-yield raw materials partially used in the present invention.

[0029] [Figure 2] This graph shows the specific gravity of conventional carbon black raw materials compared to low-yield raw materials partially used in the present invention.

[0030] [Figure 3] This graph shows the BMCI values ​​of conventional raw materials compared to low-yield raw materials partially used in the present invention.

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

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

[0033] [Figure 6] This is a cross-sectional view of a further example of a reactor suitable for preparing the carbon black of the present invention. [Modes for carrying out the invention]

[0034] The present invention relates to a method for producing carbon black using an electroheated carbon black process and utilizing low-yield carbon black raw materials as defined and described herein. The present invention further relates to carbon black produced from one or more of these methods. In the methods of the present invention, a portion of the total carbon black raw materials used can be one or more low-yield carbon black raw materials. The methods of the present invention not only allow the use of small to large quantities of low-yield carbon black raw materials, but also do not compromise the quality of the carbon black produced. Therefore, the methods of the present invention utilize carbon black raw materials that are more desirable to use for environmental and / or other reasons, and further produce carbon black comparable to carbon black produced using conventional carbon black raw materials used in furnace carbon black processes and / or conventional plasma processes.

[0035] The present invention provides a method for producing carbon black, comprising, essentially comprising, comprising, or including, combining at least one first carbon black raw material with an electrically heated gas stream (or an electrically heated carrier gas stream) to form a reaction stream. The method also comprises, essentially comprising, or including, combining at least one low-yield carbon black raw material downstream with the existing reaction stream to form carbon black and recovering the carbon black in the reaction stream. In this method, preferably, at least one low-yield carbon black raw material constitutes at least 10% by weight of the total raw material, more preferably at least 25% by weight of the total raw material, or at least 50% by weight of the total raw material, or at least 60% by weight of the total raw material, and the first carbon black raw material constitutes at least 10% by weight of the total raw material.

[0036] Another method of the present invention comprises combining a carbon black raw material, which is essentially made from, consists of, or includes at least one first carbon black raw material and at least one low-yield carbon black, with an electrically heated gas stream (or electrically heated carrier gas stream) to form a reaction stream to form carbon black, and recovering the carbon black in the reaction stream. The carbon black raw materials can be introduced as a blend, or a plurality of separate carbon black raw materials can be introduced (for example, at the same or substantially the same locations) and combined with an electrically heated gas stream. In this method, preferably, at least one low-yield carbon black raw material may constitute at least 10% by weight of the total raw material, more preferably at least 25% by weight of the total raw material or at least 50% by weight of the total raw material, and the first carbon black raw material may constitute at least 10% by weight of the total raw material.

[0037] For the purposes of the present invention, the "low yield carbon black raw material" is a carbon black raw material having at least one of the following characteristics. 1) Bureau of Mines Correlation Index (BMCI) less than 100 (providing an indicator of low aromatic content for liquid feed) (e.g., BMCI less than 99, less than 95, less than 90, less than 85, less than 80, less than 75, less than 70, e.g., BMCI between 50 and 99, or 60 and 99, or 70 and 99, or 50 and 95, or 50 and 90), and / or 2) A carbon-containing material that is a gas at room temperature (e.g., 25°C) and room pressure (1 atm), and / or 3) Atomic H:C ratio greater than 1.23 (for example, H:C ratios of 1.24 or higher, 1.25 or higher, 1.26 or higher, 1.27 or higher, 1.28 or higher, 1.29 or higher, 1.30 or higher, 1.35 or higher, 1.40 or higher, 1.45 or higher, 1.50 or higher, for example, 1.235~1.5, or 1.235~1.45, or 1.235~1.4, or 1. (235~1.35, or 1.235~1.3, or 1.235~1.29, or 1.235~1.28, or 1.235~1.27, or 1.24~1.5, or 1.25~1.5, or 1.26~1.5, or 1.27~1.5, or 1.28~1.5, or 1.29~1.5, or 1.3~1.5), and / or 4) Specific gravity of up to 1.02 (for example, up to 1.015, up to 1.01, up to 1.005, up to 1.01, up to 1.00, up to 0.99, up to 0.95, for example, 0.80~1.019, or 0.80~1.015, or 0.80~1.01, or 0.80~1.005, or 0.80~1.00, or 0.80~0.95, or 0.80~0.9, or 0.80~1.015, or 0.90~1.01, or 0.90~1.005, or 1.005~1.015).

[0038] Low-yield carbon black raw materials may only possess BMCI properties. Low-yield carbon black raw materials may only possess atomic H:C properties. Low-yield carbon black raw materials may only possess specific gravity properties. Low-yield carbon black raw materials may only possess gaseous properties.

[0039] Low-yield carbon black raw materials can possess BMCI properties and atomic H:C properties.

[0040] Low-yield carbon black raw materials can possess BMCI properties and specific gravity properties.

[0041] Low-yield carbon black raw materials can possess BMCI properties and gaseous properties.

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

[0043] Low-yield carbon black raw materials can possess BMCI properties, atomic H:C properties, and gaseous properties.

[0044] Low-yield carbon black raw materials can possess BMCI properties, atomic H:C properties, specific gravity properties, and gas properties.

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

[0046] Low-yield carbon black raw materials can possess atomic H:C properties and gaseous properties.

[0047] Low-yield carbon black raw materials can possess atomic H:C properties, specific gravity properties, and gaseous properties.

[0048] Low-yield carbon black raw materials may possess specific gravity and gas properties.

[0049] Low-yield carbon black feedstocks can be derived from sources considered to be sustainable, biological, and / or recycled. For example, low-yield carbon black feedstocks may be, or may contain, ethylene, which is a gas at room temperature and pressure. Ethylene can be produced from bio-derived ethanol, for example, from maize fermentation or other plant material fermentation. Another example of a low-yield carbon black feedstock is natural gas.

[0050] For the purposes of the present invention, the low-yield carbon black raw material may be a raw material not derived from fossil fuel-based gasoline production or coal cracking, or from cracking for the production of olefins. Therefore, the low-yield carbon black raw material is a raw material other than coal tar liquid, petroleum refined liquid, or ethylene cracker residue.

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

[0052] Figure 1 is a graph showing the atomic H:C ratio of conventional high-yield carbon black raw materials in comparison with tire pyrolysis oil (TPO), vegetable oil (Veg.Oil), and two types of gaseous raw materials (natural gas and ethylene) (Gas). For conventional raw materials, the H:C ratio is plotted for a set of approximately 1000 representative coal tar liquids, decant oils, and ECRs used as carbon black raw materials for furnace black processes between 2016 and 2021. The range of H:C values ​​can be compared with three groups of low-yield carbon black raw materials. It is clear that the H:C value of conventional raw materials is low, below 1.23 (dashed line in the figure). All of the low-yield carbon black raw materials in Figure 1 have an H:C value greater than 1.23.

[0053] Figure 2 is a graph showing examples of the specific gravity of conventional high-yield raw materials compared to tire pyrolysis oil (TPO) and vegetable oil (Veg. Oil). For conventional raw materials, the specific gravity is plotted for a collection of approximately 1000 representative coal tar liquids, decant oils, and ECRs used as carbon black raw materials for the furnace black process between 2016 and 2021. The specific gravity range is compared with two groups of low-yield carbon black raw materials. Conventional raw materials generally have a specific gravity greater than 1.02 (dashed line in the figure), while low-yield carbon black raw materials have a specific gravity of 1.02 or less.

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

[0055] Other examples of low-yield carbon black raw materials include, but are not limited to, renewable raw materials, bio-derived or bio-based raw materials, and / or other by-products of the purification process, or any combination thereof.

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

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

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

[0059] Other examples of low-yield carbon black raw materials include, but are not limited to, oils obtained from animal fats.

[0060] Other examples of low-yield carbon black raw materials include, but are not limited to, algal oil.

[0061] Other examples of low-yield carbon black raw materials include, but are not limited to, oil obtained from the thermal decomposition of sewage sludge or agricultural waste.

[0062] Other examples of low-yield carbon black raw materials include, but are not limited to, by-product liquids from the processing of bio-based materials.

[0063] Other examples of low-yield carbon black raw materials include, but are not limited to, liquids produced by the hydrothermal liquefaction of biomaterials.

[0064] Other examples of low-yield carbon black raw materials include, but are not limited to, crude tall oil, tall oil rosin, tall oil pitch, or tall oil fatty acids (e.g., from papermaking processes).

[0065] Other examples of low-yield carbon black raw materials include, but are not limited to, renewable raw materials, such as oil obtained from recycled materials.

[0066] Other examples of low-yield carbon black raw materials include, but are not limited to, oils obtained from the thermal decomposition of low-quality tires, substandard tires, or end-of-life tires.

[0067] Other examples of low-yield carbon black raw materials include, but are not limited to, oil obtained from the thermal decomposition of waste or recycled plastics.

[0068] Other examples of low-yield carbon black raw materials include, but are not limited to, oil obtained from the pyrolysis of municipal solid waste.

[0069] Other examples of low-yield carbon black raw materials include, but are not limited to, biomass, such as oils obtained from the thermal decomposition of animals or plants (e.g., vegetables) (bio-oils).

[0070] As described above, in the present invention, a portion (by weight %) of all raw materials used in the method of the present invention (introduced in a stepwise manner, as a blend, or at the same or substantially the same position in the reactor) is one or more low-yield carbon black raw materials, and a portion is not a low-yield carbon black raw material.

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

[0072] Preferably, the amount of low-yield carbon black raw material (introduced in a stepwise manner, as a blend, or at the same or nearly same position in the reactor) is at least 10% by weight, or at least 15% by weight, or at least 20% by weight, or at least 25% by weight, or at least 30% by weight, or at least 35% by weight, or at least 40% by weight, or at least 45% by weight, or at least 50% by weight, or at least 55% by weight, or at least 60% by weight, or at least 65% by weight, or at least 70% by weight, or at least 75% by weight, or at least 80% by weight, or at least 85% by weight, or at least 90% by weight, based on the total weight % of all raw materials used, but less than 100% by weight, preferably less than 99% by weight or less than 95% by weight, for example. , 10% to 95% by weight, or 10% to 90% by weight, or 15% to 90% by weight, or 20% to 90% by weight, or 25% to 90% by weight, or 30% to 90% by weight, or 35% to 90% by weight, or 40% to 90% by weight, or 45% to 90% by weight, or 50% to 95% by weight, or 10% to 80% by weight, or 10% to 70% by weight, or 10% to 60% by weight This includes percentage by weight, or 10% to 50% by weight, or 10% to 40% by weight, or 10% to 30% by weight, or 60% to 95% by weight, or 65% to 95% by weight, or 70% to 95% by weight, or 75% to 95% by weight, or 60% to 95% by weight, or 60% to 90% by weight, or 60% to 85% by weight, or 60% to 80% by weight, or 60% to 75% by weight, etc.

[0073] For the purposes of this invention, the “first carbon black raw material” or “high-yield carbon black raw material” is a raw material that is not a low-yield carbon black raw material as defined herein. The first carbon black raw material may be considered, or may be referred to as, a carbon black raw material traditionally used in the furnace carbon black process ("traditional" carbon black raw material). As will be further discussed herein, the first carbon black raw material may optionally be a blend of raw materials containing a small amount of low-yield carbon black raw material.

[0074] The primary carbon black raw materials typically come from decant or slurry oil, coal tar or coal tar distillate, or families of ethylene or phenol cracker residues. Their distinct characteristics in typical furnace carbon black production are further described below.

[0075] The first carbon black raw material possesses all three of the following properties: 1) At least 100 (for example, at least 101, at least 102, at least 103, at least 104, at least 105, at least 110, at least 115, at least 120, at least 130, at least 140, at least 150, at least 160, at least 170, for example, 100-180, 101-180, 102 BMCI (for the following ranges): ~180, 103~180, 104~180, 105~180, 110~180, 115~180, 120~180, 130~180, 140~180, 150~180, 160~180, 100~175, 100~170, 100~165, 110~175, 115~175, 120~175, 125~170, 130~170) 2) Specific gravity greater than 1.02 (for example, greater than 1.025, greater than 1.03, greater than 1.035, greater than 1.04, greater than 1.05, for example, 1.021~1.3, or 1.025~1.3, or 1.03~1.3, or 1.05~1.3, or 1.07~1.25), 3) A C:H ratio of up to 1.23 (for example, up to 1.22, up to 1.21, up to 1.2, up to 1.15, up to 1.1, up to 1.05, up to 1, up to 0.9, up to 0.8, for example, 1.225~0.7, 1.225~0.8, 1.225~0.9, 1.225~1, 1.225~1.1, 1.22~0.7, 1.21~0.7, 1.2~0.7). As an alternative, the first carbon black raw material may also be liquid at room temperature and room pressure (e.g., 25°C and 1 atm). Despite being liquid, the first carbon black raw material may be pitch or a similar material with extremely high viscosity and does not need to exhibit remarkable fluidity.

[0076] Examples of the first carbon black raw materials are shown in Table 2 below and include coal tar, liquid distilled from coal tar, decant or slurry oil obtained from catalytic cracking, and residue oil from ethylene cracking. As shown in Table 2, these raw materials have an H:C ratio of up to 1.23, a specific gravity greater than 1.02, and a BMCI value of at least 100.

[0077] [Table 2]

[0078] The first carbon black raw material may also include fractions obtained from the refining or distillation of tire pyrolysis oil. Pyrolysis can be achieved by any method known to those skilled in the art. Examples of such methods, but not limited to those found in U.S. Patent No. 8,350,105 and U.S. Patent Publication No. 2018,032,0082, both of which are incorporated herein by reference in their entirety. Distillation of the resulting oil can also be achieved by any method known to those skilled in the art. Examples of such methods, but not limited to those found in U.S. Patent No. 9,920,262 and International Publication No. 2019,236,214, both of which are incorporated herein by reference. Distillation of tire pyrolysis oil can provide at least one fraction that can be used as the first carbon black raw material, and at least one fraction that is a low-yield carbon black raw material. In fact, distillation may yield a lighter fraction that can be used more economically in other unit processes of the carbon black production process, for example, as fuel for a dryer for carbon black, or as fuel for a heater for preheating either or both of the first or second carbon black raw materials, as disclosed in U.S. Patent Application Publication No. 20130039841, the contents of which are incorporated herein by reference. Thus, the integration of a distillation process with a carbon black reactor can reconcile the economic and environmental benefits from the recycling of carbon black-filled tires.

[0079] As an option, in the method of the present invention, based on the total amount of raw materials used (in weight %), the first carbon black raw material is at least 10% by weight, or at least 15% by weight, or at least 20% by weight, or at least 25% by weight, or at least 30% by weight, or at least 35% by weight, or at least 40% by weight, or at least 45% by weight, or at least 50% by weight, or at least 55% by weight, or at least 60% by weight, or at least 65% by weight, or at least 70% by weight. , or at least 75% by weight, or at least 80% by weight, or at least 85% by weight, or at least 90% by weight, but less than 100% by weight, preferably less than 99% by weight or less than 95% by weight, for example, 10% to 95% by weight, or 10% to 90% by weight, or 15% to 90% by weight, or 20% to 90% by weight, or 25% to 90% by weight, or 30% to 90% by weight, or 35% to 90% by weight, or 40% to 90% by weight, or 45% to 90% by weight, or 50% to 95% by weight, or 10% to It can be used in amounts such as 80% by weight, or 10% to 70% by weight, or 10% to 60% by weight, or 10% to 50% by weight, or 10% to 40% by weight, or 10% to 30% by weight, or 60% to 95% by weight, or 65% to 95% by weight, or 70% to 95% by weight, or 75% to 95% by weight, or 60% to 95% by weight, or 60% to 90% by weight, or 60% to 85% by weight, or 60% to 80% by weight, or 60% to 75% by weight (introduced in a stepwise manner, or as a blend, or reversed). It is introduced into the same or nearly the same location within the container. Based on the total amount of raw materials used (in weight %), other amounts of the first carbon black raw material may be 49% by weight or less, 45% by weight or less, 40% by weight or less, 35% by weight or less, 30% by weight or less, 25% by weight or less, 20% by weight or less, 15% by weight or less, 10% by weight or less, 9% by weight or less, 8% by weight or less, 7% by weight or less, 6% by weight or less, for example, 5% to 49% by weight, or 5% to 45% by weight, or 10% to 40% by weight, or 10% to 35% by weight, or 10% to 30% by weight.

[0080] The first carbon black raw material may be liquid under room temperature (e.g., 25°C) and atmospheric conditions (e.g., 1 atm). “Rich in aromatic species” means that the raw material contains a large amount of aromatic compounds. For example, a large amount of aromatic compounds means that the total weight percentage of aromatic compounds present is at least 20% by weight, or that it has at least 100 BMCI, or both. The first carbon black raw material can be heated to a vapor form, which may result in an aromatic species-rich vapor, or may actually be used as an aromatic species-rich vapor.

[0081] With respect to the steps of the method of the present invention, some methods of the present invention include combining an electrically heated gas stream (or electrically heated carrier gas stream) with a first carbon black raw material and a low-yield carbon black raw material. Furthermore, as described above, the first carbon black raw material and the low-yield carbon black raw material can be introduced or combined with the heated gas stream in stages (for example, by introducing the first carbon black raw material first and then introducing the low-yield carbon black raw material downstream, or by introducing or combining a blend of the first carbon black raw material and the low-yield carbon black raw material with the heated gas stream), or by introducing or combining the first carbon black raw material and the low-yield carbon black raw material with the heated gas stream at the same or substantially the same position in the carbon black reactor).

[0082] In another method of the present invention, the carbon black raw material or a portion thereof is electrically heated so that thermal decomposition of the raw material occurs.

[0083] In the method of the present invention, the electrical heating of either the carrier gas and / or the carbon black raw material may be direct or indirect (for example, direct means that the heating element is in contact with the carrier gas and / or the raw material).

[0084] There are at least four methods that can be used for the purposes of the present invention to generate an electrically heated gas flow. In any of these methods, electrical energy is used to heat the carrier gas and / or carbon black raw material so that at least a portion of the carbon black raw material undergoes thermal decomposition.

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

[0086] In the first method, an arc is used to electrically heat a carrier gas, which can then be brought into contact with the carbon black raw material(s) described herein. Because the arc generates plasma, this method is sometimes called a plasma process.

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

[0088] In the third method, an inductive or microwave-based plasma is used to heat either the carrier gas or the carbon black raw material itself, without direct contact between the gas and the electrode.

[0089] In the fourth method, a plasma arc or heating element is used to heat the carbon black raw material by bringing it into direct contact with the material. U.S. Patents 8,221,689 and 7,563,525 further describe these methods that may be used in the present invention.

[0090] Methods used to form or produce electrically heated gas streams and / or carbon black raw materials, as well as apparatus / devices and conditions / parameters for doing so, are commercially available and can be employed or utilized herein for the methods of the present invention.

[0091] For the sake of more detail, and simply as examples, the first method (plasma process using a carrier gas) and the second method (electric heating process using a carrier gas) will be described in more detail.

[0092] A plasma process can be used to produce carbon black by heating a suitable carrier gas stream to a high temperature so that thermal decomposition of the carbon black raw material can occur when combined with an electrically heated carrier gas stream (e.g., above 3000°C). Heating can be achieved by an electric arc. Once the heated carrier gas stream is formed, the carbon black raw material can be introduced into or combined with this heated carrier gas stream. The high-temperature carrier gas stream contains a substantial portion of the energy required to drive the rapid high-temperature thermal decomposition of the raw material into carbon black and by-product gases. Further details of this process, which can be employed in the method of the present invention, are described in U.S. Patent No. 9,574,086 (which is incorporated herein by reference in its entirety).

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

[0094] Next, the heated carrier gas is combined with or mixed with carbon black raw materials, which can be introduced, for example, by injectors 7 and 8. Injector 7 may be positioned at a location having a diameter narrower than diameter 5. In Figure 4, injector 8 is shown downstream of injector 7 in the throat 9, which has the narrowest diameter of the carbon black reactor 10. Alternatively, injector 8 may be positioned downstream of injector 7 but in a region having a wider diameter than throat 9. Injector 7 can, for example, introduce or inject a first carbon black raw material into the reactor, and further carbon black raw materials, such as low-yield carbon black raw materials, can be introduced at injection point 8. The distance between injectors 7 and 8 only needs to be long enough for the first carbon black raw material injected into the reactor 10 by injector 7 to be mixed with the carrier gas. In the present invention, generally, at least a portion, if not all, of the first carbon black raw material can be injected or introduced at least before introducing the low-yield carbon black raw material into the reactor. Preferably, the majority of the first carbon black feedstock is introduced before any low-yield carbon black feedstocks are introduced. To assist this mixing process, a high-temperature carrier gas can be forced into the narrow throat 9 to increase turbulence and produce rapid mixing. Since the first carbon black feedstock is typically injected as a liquid, the increased turbulence generated by contraction can also help atomize the droplets.

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

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

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

[0098] The elements 16 may be heated by exposure to an electric current passing through them, or by induction heating by exposure to, for example, microwaves, radio frequencies, or other suitable electromagnetic radiation. As is known in the art, the electromagnetic energy in microwave radiation causes electrons to move within the rod, thereby heating the rod. This method allows for a reactor without direct penetration for electrical connections, which may be beneficial in certain examples. For example, a SiC rod becomes hot when subjected to microwave radiation. In this embodiment, there is no need for crossing wires or other conductors within the heating chamber, thus reducing the complexity of the design.

[0099] The method of the present invention can be applied to electrically heated processes and reactors as shown in Figure 6. Figure 6 shows a cross-sectional view of another example of a carbon black reactor 20 having similar features to the apparatus 10 in Figure 4. In contrast to Figure 4, the reactor 20 features two narrowing throats 64 and 65 at both ends of an intermediate chamber 58. A hot carrier gas from duct 2 is supplied toward the narrowing throats 64. The first carbon black raw material is supplied through injectors 7 or 8, or both simultaneously, and mixed with the carrier gas.

[0100] In Figure 6, the length between the carrier gas inlet and the center of the constriction section 64 is shown as length 60. This length can preferably be 1 to 10 times the narrowest diameter of the first constriction section 64. By adjusting this length, it is possible to balance the structure of the carbon black and the economics of the process. The height or diameter 5 is shown relative to the heating gas chamber, and this height is greater than the height or diameter 64. The height or diameter 64 can be at least 20%, at least 30%, at least 40%, or at least 50% smaller than the height or diameter 5.

[0101] Following the introduction of the first carbon black raw material, the high-temperature gas stream mixed with the raw material enters the first reaction chamber 58. The purpose of the chamber is to provide a residence time so that the pyrolysis reaction producing carbon black can complete its induction time and begin, and optionally generate a seed particle population for subsequent structural growth. The length of this chamber 66 can typically be 1 to 20 times the narrowest diameter of the first reduction section 64.

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

[0103] The distance 66 between the shrinkage throats 64 and 65 can be greater than the diameter 64 and can be adjusted to change or optimize product characteristics. The shrinkage throats 64 and 65 can have the same or different diameters. Those skilled in the art will understand how to adjust these diameters to obtain the desired mixing characteristics of the reaction flow.

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

[0105] In an alternative configuration, the first carbon black raw material is introduced at positions 7 and / or 8, followed by the introduction of the low-yield carbon black raw material at positions 8 and / or 59 (and / or positions between these positions), which can also be introduced simultaneously if both positions are used. This can provide a beneficial trade-off between structural capability and yield or process economics. In all of the above embodiments, at least a portion, preferably a large portion, of the first carbon black raw material used, for example, all of the first carbon black raw material, is introduced before and upstream of the low-yield carbon black raw material.

[0106] The present invention enables gas-phase carbon black raw materials or other non-traditional low-yield carbon black raw materials to produce a larger carbon black structure than can be achieved in conventional methods that may use non-traditional carbon black raw materials.

[0107] Furthermore, the present invention makes it possible to lower the temperature required to produce a given surface area compared to the exclusive use of non-traditional raw materials. This means that less carrier gas is required, reducing the capital cost in the electric heating process. For example, the temperature can be reduced by 2% to 5% or more.

[0108] The injector 7 can, for example, introduce or inject the first carbon black raw material into the reactor. Alternatively, the first carbon black raw material may also be introduced into the chamber using an axial pipe or lance. As a further alternative, the first carbon black raw material may be injected or introduced simultaneously by multiple methods. Lances or any other injectors exposed to the reactor may need to be cooled or protected from excessive heat in the reactor by methods known in the art.

[0109] In this invention, optionally, at least a portion (but not all) of the first carbon black raw material may be injected or introduced into the reactor before the low-yield carbon black raw material is introduced. Preferably, the amount of the first carbon black raw material injected or introduced into the reactor before the low-yield carbon black raw material is introduced is greater than the total amount of the first carbon black raw material introduced in any later stage. That is, the majority (>50%) of the first carbon black raw material used in the reactor is introduced or injected in the first stage (for example, at position / injector 7 in Figure 4).

[0110] Carbon black raw materials can be injected into a gas flow through one or more nozzles designed for optimal distribution of the raw materials into the heated carrier gas flow. Such nozzles may be single-fluid or dual-fluid. Dual-fluid nozzles can atomize the raw materials using, for example, steam, air, or nitrogen. Single-fluid nozzles may be pressure-atomized, or the raw materials may be injected directly into the gas flow. In the latter case, atomization is caused by the force of the gas flow.

[0111] The carbon black raw material may be injected by an axial injection lance, or a central pipe may be used, and / or one or more radial lances may be used, arranged around the reactor in a plane perpendicular to the flow direction. The reactor may include several planes with radial lances along the flow direction. Spray nozzles or injection nozzles may be placed on the heads of the lances, thereby mixing the raw material with the flow of heated gas.

[0112] The first carbon black raw material can be introduced at one or more of these locations, at two locations simultaneously, or at three or more locations simultaneously. The method and division of the first raw material injection can be modified between these locations, if two or more locations are used, to alter the product properties and process economics. The injector and the reaction chamber(s) themselves can be cooled as needed by methods known in the art.

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

[0114] Similarly, the low-yield carbon black raw material may optionally be a blend of the high-yield carbon black raw material and a non-high-yield carbon black raw material that does not satisfy at least one of the BMCI, H:C, and specific gravity parameters required for the first carbon black raw material, provided that the blend also does not satisfy at least one of the BMCI, H:C, and specific gravity parameters required for the first carbon black raw material. The non-high-yield carbon black raw material may be present in an amount exceeding 50% by mass of the total raw materials in this optional blend (e.g., 60% to 99% by weight, or 50.5% to 99.5% by weight of non-high-yield carbon black raw material).

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

[0116] As an option, one method of the present invention includes the step of introducing at least one first carbon black raw material into a carbon black reactor together with a heating gas flow to form a reaction flow. The first carbon black raw material may be one type or a combination of two or more different first carbon black raw materials. If two or more types of raw materials are used as the first carbon black raw material, the multiple first carbon black raw materials may be blended together and injected as a single blended raw material through one or more locations, or each raw material may be injected separately into the reactor at the same or different locations.

[0117] As an option, one method of the present invention includes the step of introducing at least one low-yield carbon black feedstock into the reaction stream. The low-yield carbon black feedstock may be one type or a combination of two or more different low-yield carbon black feedstocks. When two or more types of feedstocks are used as low-yield carbon black feedstocks, the multiple low-yield carbon black feedstocks may be blended together and injected as a single blended feedstock through one or more locations, or each feedstock may be injected separately into the reactor at the same or different locations.

[0118] Generally, any of the carbon black raw materials used in any of the methods of the present invention can be injected into the reactor in a single or multiple flow using an injector that penetrates the internal region of the heated gas flow. The injector can ensure a higher mixing ratio and shear between the heated gas flow and the carbon black raw material(s). This ensures that the raw materials are thermally decomposed, preferably at a fast rate and / or in high yield, to form the carbon black of the present invention.

[0119] The first carbon black raw material can be introduced at one or more locations in the reactor. In one embodiment of the present invention, the low-yield carbon black raw material can be introduced at one or more locations in the reactor. As shown, in this method of the present invention, one or more locations in the reactor can be downstream(or more) of one or more locations where the first carbon black raw material is injected or introduced. The introduction of the low-yield carbon black raw material can be carried out using one or more injectors (e.g., metal pipes(or more) located on the wall of the reactor) to introduce the raw material into the reactor. The injectors may have an injector head or a spray head at their tip. The injectors on the tip may have, for example, one or more holes (two, three, four or more) around the tip (multiple holes that are roughly evenly spaced).

[0120] As an alternative, the introduction of low-yield carbon black feedstock into the reactor and reaction flow can be done, for example, by introducing the feedstock perpendicular to the lateral flow of the reaction flow through the reactor, as shown in Figures 4-6. Perpendicular can be ±15 degrees from true vertical injection of the feedstock into the reaction flow.

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

[0122] As an alternative, the introduction of the low-yield carbon black feedstock into the reactor and reaction flow may be carried out at a distance from the location where the first carbon black feedstock is introduced or injected within the reactor, and this distance may be at least 1 or at least 2 times the narrowest diameter of the reactor's first chamber 6, e.g., diameter 9 or 64 (or at least 2 times the diameter of the reactor into which the first carbon black feedstock is introduced or injected). This distance may be at least 2.25 times, at least 2.5 times, at least 2.75 times, at least 3 times, at least 3.25 times, at least 3.5 times, at least 3.75 times, or at least 4 times the diameter of the reactor's first chamber (e.g., when the carrier gas and feedstock are electrically heated) (or at least 2.25 times, at least 2.5 times, at least 2.75 times, at least 3 times, at least 3.25 times, at least 3.5 times, at least 3.75 times, or at least 4 times the diameter of the reactor into which the first carbon black is introduced or injected).

[0123] Low-yield carbon black raw material can be introduced at positions 8 and / or 59 through one or more injectors.

[0124] After the raw materials (first carbon black raw material and low yield carbon black raw material) are combined with a heated gas stream, the method of the present invention generally includes a step of rapidly cooling the reaction.

[0125] The reaction is stopped in the quenching zone of the reactor (see 62 in Figure 6). As shown in Figure 6, quenching 62 is located downstream of the final raw material injection zone and involves spraying a quenching fluid, such as water, into the flow of newly formed carbon black particles. Generally, quenching helps to cool the carbon black particles, lower the temperature of the gas flow, and reduce the reaction rate. Distance 67 is the distance from the starting point of the final raw material injection point to the quenching point 62 and varies depending on the location of the quenching. Optionally, quenching may be stepwise or performed at several points in the reactor. Pressure spraying, gas atomization spraying, or other quenching techniques are also available. With regard to completely quenching the reaction for forming carbon black, any means known to those skilled in the art for quenching the reaction downstream of the introduction of carbon black production raw materials can be used. For example, a quenching fluid, which may be water or other suitable fluid, can be injected to stop the chemical reaction.

[0126] After rapid cooling, the cooled gas and carbon black pass downstream to any conventional cooling means and a separation means from which the product is recovered. Separation of carbon black from the gas stream can be easily achieved by conventional means such as a dust collector, cyclone separator, bag filter, or other means known to those skilled in the art. After separating the carbon black from the gas stream, the carbon black can optionally be subjected to a pelletizing step.

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

[0128] In any of the methods of the present invention, the carbon black is optionally formed completely in situ in the reactor.

[0129] As an option, one or more of the carbon black raw materials or other components used in the method of the present invention can be preheated before being introduced into the reactor. For example, U.S. Patent No. 3,095,273 issued to Austin on June 25, 1963; U.S. Patent No. 3,288,696 issued to Orbach on November 29, 1966; U.S. Patent No. 3,984,528 issued to Cheng et al. on October 5, 1976; U.S. Patent No. 4,315,901 issued to Cheng et al. on February 16, 1982; U.S. Patent No. 4,765,964 issued to Gravley et al. on August 23, 1988. Appropriate preheating temperatures and / or preheating techniques can be used in the present invention, as described in U.S. Patent No. 5,997,837 issued to Lynum et al. on December 7, 999, U.S. Patent No. 7,097,822 issued to Godal et al. on August 29, 2006, U.S. Patent No. 8,871,173(B2) issued to Nester et al. on October 28, 2014, or Canadian Patent No. 682982 (all documents are incorporated herein by reference). Alternatively, or in addition, low-yield carbon black raw materials may be preheated to a higher temperature than typical for high-yield raw materials. For example, low-yield carbon black raw materials can be heated to temperatures above 600°C, e.g., 600-800°C, even at ambient pressure. Because low-yield carbon black raw materials have a low concentration of asphaltene, heating to such high temperatures does not produce significant amounts of coke or other solid non-carbon black species. Alternatively, or in addition, one or more of the carbon black raw materials may be combined with an extender fluid before being introduced into the reactor, for example, as described in U.S. Patent No. 10,829,642 to Unrau (the entire contents of which are incorporated herein by reference).

[0130] Alternatively, this method may be carried out in the absence of at least one Group IA or Group IIA element (or its ion) of the periodic table, or at least one substance containing it.

[0131] As an option, any of the methods of the present invention may include a step of introducing at least one substance which is or contains at least one Group IA or Group IIA element (or an ion thereof) of the periodic table. Preferably, the substance contains at least one alkali metal or alkaline earth metal. Examples include lithium, sodium, potassium, rubidium, cesium, francium, calcium, barium, strontium, or radium, or combinations thereof. Any mixture of one or more of these components may be present in the substance. Such substance may be a solid, a solution, a dispersion, a gas, or any combination thereof. Two or more substances having the same or different Group IA or Group IIA metals may be used. If multiple substances are used, these substances may be added together, separately, sequentially, or at different reaction sites. For the purposes of the present invention, the substance may be the metal (or metal ion) itself, a compound containing one or more of these elements (including salts containing one or more of these elements), and so on. Preferably, the substance can introduce a metal or metal ion into the reaction underway to form the carbon black product. For the purposes of the present invention, preferably, the substance is introduced before complete quenching as described above. For example, the substance can be added at any point before complete quenching, including before the introduction of one or both of the carbon black production raw materials, during the introduction of one or both of the carbon black production raw materials, after the introduction of one or all of the carbon black production raw materials, or after the introduction of all raw materials but before complete quenching. Two or more points of introduction of the substance can be used. The amount of the group IA or group IIA metal-containing substance can be any amount as long as a carbon black product can be formed. For example, the amount of substance can be added such that 200 ppm or more of the group IA or group IIA element is present in the carbon black product that is ultimately formed.Other amounts of group IA or group IIA elements present in the formed carbon black product include approximately 200 ppm to approximately 5000 ppm or more, and other ranges include approximately 300 ppm to approximately 1000 ppm, or approximately 500 ppm to approximately 1000 ppm. These levels may relate to metal ion concentrations. As mentioned above, these amounts of group IA or group IIA elements present in the formed carbon black product may relate to one element or two or more group IA or group IIA elements, and therefore may represent the total amount of group IA or group IIA elements present in the formed carbon black product. Substances can be added in any form, including any conventional means. In other words, substances can be added in the same way that carbon black production raw materials are introduced. Substances can be added as gases, liquids, or solids, or any combination thereof. Substances can be added at one or more locations, and can be added in a single or multiple flow. Substances can be mixed with raw materials, fuels, and / or oxidizers before or during their introduction.

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

[0133] Carbon black can be characterized by its specific surface area, structure, aggregate size, shape, and distribution, as well as / or surface chemical and physical properties. The properties of carbon black are determined analytically by tests known in the art. For example, nitrogen adsorption surface area, and statistical thickness surface area (STSA), another measure of surface area, are determined by nitrogen adsorption according to ASTM test procedure D6556. Iodine value can be measured using ASTM procedure D1510. Carbon black "structure" represents the size and complexity of carbon black aggregates formed by the fusion of primary carbon black particles with one another. As used herein, carbon black structure can be measured as oil absorption (OAN) of unground carbon black, expressed as the number of milliliters of oil per 100 grams of carbon black, according to the procedure described in ASTM D2414. Compression sample oil absorption (COAN) measures the portion of the carbon black structure that does not readily change with the application of mechanical stress. COAN is measured according to ASTM D3493. The aggregate size distribution (ASD) is measured according to the ISO 15825 method using a disk centrifuge with a Brookhaven Instruments Model BI-DCP.

[0134] Carbon black materials with properties suitable for specific applications may be selected and defined by ASTM standards (see, for example, ASTM D1765 Standard Classification System for Carbon Blacks Used in Rubber Products), such as the N100, N200, N300, N500, N600, N700, N800, or N900 series of carbon blacks, such as N110, N121, N220, N231, N234, N299, N326, N330, N339, N347, N351, N358, N375, N539, N550, N650, N660, N683, N762, N765, N774, N787, or N990 carbon blacks, or other commercial grade standards.

[0135] Carbon black is 5 m

[0137] , 2 , 2 , 2 , 2 , 2 , 2 , , 2 , 2 , 2 , / g to 250 m 2 / g, 11 m 2 / g to 250 m 2 / g, 20 m 2 / g to 250 m<​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​The oil absorption rate (OAN) can be 40 mL / 100g to 200 mL / 100g, for example, 60 mL / 100g to 200 mL / 100g, for example, 80 mL / 100g to 200 mL / 100g, for example, 100 mL / 100g to 200 mL / 100g, or 120 mL / 100g to 200 mL / 100g, mL / 100g, 140 mL / 100g to 200 mL / 100g, 160 mL / 100g to 200 mL / 100g, or for example, 40 mL / 100g to 150 mL / 100g, or 40 mL / 100g to 150 mL / 100g.

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

[0139] Carbon black can be a carbon product containing silicon-containing species and / or metal-containing species, which can be achieved by including a further step of introducing such species together with or in addition to any or both of the carbon black production raw materials. For the purposes of the present invention, carbon black can be a multiphase aggregate (also known as silicon-treated carbon black, e.g., ECOBLAK® material from Cabot Corporation) comprising at least one carbon phase and at least one metal-containing species phase or silicon-containing species phase.

[0140] As described above, the carbon black can be rubber black, in particular, a reinforced grade of carbon black or a semi-reinforced grade of carbon black.

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

[0142] Carbon black can be surface-modified in accordance with U.S. Patent No. 8,975,316 to Belmont et al., the contents of which are incorporated herein by reference in their entirety.

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

[0144] Oxidized (modified) carbon black can be prepared in a manner similar to that used for carbon black, for example, as described in U.S. Patent No. 7,922,805 issued to Kowalski et al. on April 12, 2011, and U.S. Patent No. 6,471,763 issued to Karl on October 29, 2002 (these are incorporated herein by reference in their entirety). Oxidized carbon black is obtained by oxidizing with an oxidizing agent to introduce ionic groups and / or ionizable groups onto the surface. Such particles may have a higher degree of oxygen-containing groups on the surface. Examples of oxidizing agents include, but are not limited to, oxygen gas, ozone, peroxides such as hydrogen peroxide, persulfates including sodium persulfate and potassium persulfate, hypohalites such as sodium hypochlorite, oxidizing acids such as nitric acid, and transition metal-containing oxidizing agents such as permanganates, osmium tetroxide, chromium oxide, or cerium ammonium nitrate. Mixtures of oxidizing agents, in particular mixtures of gaseous oxidizing agents such as oxygen and ozone, can also be used. Other surface modification methods, such as chlorination and sulfonylation, can also be used to introduce ionic groups or ionizable groups. Carbon black can be surface modified by any method known to those skilled in the art. For example, carbon black can be heat-treated as described in U.S. Patent No. 1,0767028 (the entirety of which is incorporated herein by reference).

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

[0146] Carbon black can be incorporated into rubber articles used, for example, in tire treads, particularly treads; sub-treads; wire skims; sidewalls; cushioning rubber for retreaded tires; and other tire applications, such as those used in tires for passenger cars, light vehicles, trucks and buses, off-road ("OTR") tires, and aircraft tires.

[0147] In other applications, the particles can be used in industrial rubber articles such as engine mounts, hydro mounts, bridge bearings and seismic isolation devices, tank trucks or treads, mining belts, hoses, gaskets, seals, blades, gap fillers, bumpers, and vibration damping components.

[0148] Carbon black may be added in place of or in addition to a primary reinforcing agent for tire components and / or other industrial rubber end applications. Carbon black may 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.

[0149] Alternatively, carbon black may be mixed with rubber by a liquid masterbatch process. For example, a slurry containing the particles described herein may also be combined with an elastomer latex in a vat and then coagulated by adding a coagulant such as an acid using the technique described in U.S. Patent No. 6,841,606.

[0150] Carbon black can be introduced in accordance with U.S. Patent No. 6,048,923, issued to Mabry et al. on April 11, 2000, which is incorporated herein by reference in its entirety. For example, a method for preparing an elastomer masterbatch may include simultaneously supplying a granular packing fluid and an elastomer latex fluid to the mixing zone of a solidification reactor. The solidification zone extends from the mixing zone and preferably has a gradually increasing cross-sectional area downstream from the inlet end to the discharge end. The elastomer latex may be natural or synthetic, and the granular packing includes, is essentially, or consists of the materials described above. The granular packing is preferably supplied to the mixing zone as a continuous high-speed jet of injection fluid, and the latex fluid is supplied at a low speed. The velocity, flow rate, and particle concentration of the particulate filler fluid are sufficient to cause high-shear mixing of the latex fluid and turbulent mixing of the mixture flow in at least the upstream portion of the solidification zone, thereby substantially completely solidifying the elastomer latex with the particulate filler before the discharge end. Substantially complete solidification can be achieved without the need for an acid or salt solidifying agent. Additional elastomers may be added to the material coming out of the discharge end of the solidification reactor, as disclosed in U.S. Patent No. 6,075,084, which is incorporated herein by reference in its entirety. The solidified material may then be fed to a dewatering extruder, as disclosed in U.S. Patent No. 6,929,783, which is incorporated herein by reference in its entirety. Other examples of preferred masterbatch processes are disclosed in U.S. Patent No. 6,929,783 by Chung et al., U.S. Patent Application Publication No. 2012 / 0264875(A1) by Berriot et al., U.S. Patent Application Publication No. 2003 / 0088006(A1) by Yanagisawa et al., and European Patent No. 1834985(B1) issued to Yamada et al.

[0151] Carbon black can be evaluated in appropriate rubber formulations using natural or synthetic rubber. The appropriate amount of carbon black to use can be determined by conventional experiments and calculations, taking into account factors such as the typical filling amount of standard ASTM black in comparable manufacturing processes, parameters specific to the technology and / or equipment used, the presence or absence of other additives, and the desired properties of the final product.

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

[0153] Appropriate tests include the green rubber test, the curing test, and the cured rubber test. Among the appropriate green rubber tests, ASTM D4483 provides a test method for the ML1+4 Mooney viscosity test at 100°C. The scorch time is measured according to ASTM D4818.

[0154] The hardening curve was obtained using a rubber processing tester (RPA2000) at 0.5°, 100 cpm, and 150°C (NR) to 160°C (SBR) according to ASTM D5289.

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

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

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

[0158] The iodine value (I2 No.) is determined according to ASTM test procedure D1510. The STSA (Statistical Thickness Surface Area) is determined based on ASTM test procedure D-5816 (measured by nitrogen adsorption). The OAN is determined based on ASTM D2414. The COAN is determined based on ASTM D3493 (e.g., D3493-20).

[0159] Unless otherwise specified, all material percentages expressed herein as percentages are weight percentages.

[0160] The present invention will be further illustrated by the following embodiments, which are intended to be essentially illustrative.

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

[0162] 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.

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

[0164] 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. The following embodiments can be cited as examples of the present invention. (Note 1) A method for producing carbon black, The method involves electrically heating a carrier gas to form a heated carrier gas, and then contacting the heated carrier gas to cause thermal decomposition of at least a portion of the carbon black raw material within the carbon black reactor, wherein the carbon black raw material comprises at least one first carbon black raw material and at least one low-yield carbon black raw material. The method involves combining the at least one first carbon black raw material with the heated carrier gas to form a reaction flow, wherein the at least one first carbon black raw material constitutes at least 10% by weight of the total carbon black raw material. The carbon black is formed by combining at least one low-yield carbon black raw material downstream of the existing reaction stream, wherein the at least one low-yield carbon black raw material constitutes at least 10% by weight of the total carbon black raw material. To recover the carbon black in the reaction stream, The first carbon black raw material is liquid at room temperature and room pressure, and has the following properties: Bureau of Mines Correlation Index (BMCI, U.S. Bureau of Mines Index) 100 or more, Atomic H:C ratio of 1.23 or less, Specific gravity over 1.02, The low-yield carbon black raw material has the following characteristics: Bureau of Mines Correlation Index (BMCI) less than 100, or Atomic H:C ratio greater than 1.23, or Specific gravity 1.02 or less, Having at least one of the following, It is a gas at room temperature and room pressure. A method wherein the at least one low-yield carbon black raw material is present in an amount of 10% to 90% by weight based on the total carbon black raw material, and the at least one first carbon black raw material is present in an amount of 10% to 90% by weight based on the total carbon black raw material. (Note 2) A method for producing carbon black, The method involves electrically heating a carrier gas to form a heated carrier gas, and then contacting the heated carrier gas to cause thermal decomposition of at least a portion of the carbon black raw material within the carbon black reactor, wherein the carbon black raw material comprises at least one first carbon black raw material and at least one low-yield carbon black raw material. The at least one first carbon black raw material and the at least one low-yield carbon black raw material are combined with the heated carrier gas as a blend or as separate additives, at the same or substantially the same position, to form a reaction flow, wherein the at least one first carbon black raw material constitutes at least 10% by weight of the total carbon black raw material, and the at least one low-yield carbon black raw material constitutes at least 10% by weight of the total carbon black raw material. To recover the carbon black in the reaction stream, The first carbon black raw material is liquid at room temperature and room pressure, and has the following properties: Bureau of Mines Correlation Index (BMCI, U.S. Bureau of Mines Index) 100 or more, Atomic H:C ratio of 1.23 or less, Specific gravity over 1.02, The low-yield carbon black raw material has the following characteristics: Bureau of Mines Correlation Index (BMCI) less than 100, or Atomic H:C ratio greater than 1.23, or Specific gravity 1.02 or less, Having at least one of the following, It is a gas at room temperature and room pressure. A method wherein the at least one low-yield carbon black raw material is present in an amount of 10% to 90% by weight based on the total carbon black raw material, and the at least one first carbon black raw material is present in an amount of 10% to 90% by weight based on the total carbon black raw material. (Note 3) A method for producing carbon black, The method involves electrically heating at least one first carbon black raw material to form a reaction flow, causing thermal decomposition of at least a portion of the at least one first carbon black raw material to occur in a carbon black reactor, wherein the at least one first carbon black raw material constitutes at least 10% by weight of the total carbon black raw material. The carbon black is formed by combining at least one low-yield carbon black raw material downstream of the existing reaction stream, wherein the at least one low-yield carbon black raw material constitutes at least 10% by weight of the total carbon black raw material. To recover the carbon black in the reaction stream, The first carbon black raw material is liquid at room temperature and room pressure, and has the following properties: Bureau of Mines Correlation Index (BMCI, U.S. Bureau of Mines Index) 100 or more, Atomic H:C ratio of 1.23 or less, Specific gravity over 1.02, The low-yield carbon black raw material has the following characteristics: Bureau of Mines Correlation Index (BMCI) less than 100, or Atomic H:C ratio greater than 1.23, or Specific gravity 1.02 or less, Having at least one of the following, It is a gas at room temperature and room pressure. A method wherein the at least one low-yield carbon black raw material is present in an amount of 10% to 90% by weight based on the total carbon black raw material, and the at least one first carbon black raw material is present in an amount of 10% to 90% by weight based on the total carbon black raw material. (Note 4) The method according to any one of the appendices 1 to 3, further comprising electrically heating the at least one low-yield carbon black raw material. (Note 5) The method according to Appendix 4, wherein electrically heating the at least one low-yield carbon black raw material includes heating the low-yield carbon black raw material to a temperature of 600 to 800°C. (Note 6) The method according to Appendix 1 or 2, further comprising electrically heating at least one of the at least one first carbon black raw material and the at least one low-yield carbon black raw material. (Note 7) The method according to Appendix 1 or 2, wherein the electrically heated method is achieved by an arc. (Note 8) The method according to Appendix 1 or 2, wherein the electrically heated state is achieved using a resistor or induction-based heating element. (Note 9) The method according to Appendix 8, wherein the heating element is magnesium oxide or yttria-stabilized zirconia. (Note 10) The method according to any one of the appendices 1 to 9, wherein the heated carrier gas has a temperature of over 2000°C. (Note 11) The method according to any one of the appendices 1 to 3, wherein the electrically heating is achieved by an induction or microwave-based method that prevents direct contact between the electrode and the carrier gas or carbon black raw material. (Note 12) The method according to Appendix 3, wherein the electrically heated material is heated by a plasma arc or heating element in direct contact with the carbon black raw material. (Note 13) The low-yield carbon black raw materials are as follows: a) The Bureau of Mines Correlation Index (BMCI) is less than 95, or b) Whether the gas is present at room temperature and room pressure, or c) The atomic H:C ratio is greater than 1.3, or d) The specific gravity is 1.0 or less. The method described in any one of the appendices 1 to 12, which is at least one of the methods described in each of the appendices 1 to 12. (Note 14) The method according to any one of the appendices 1 to 13, wherein the low-yield carbon black raw material has a specific gravity of less than 1.02. (Note 15) The method according to any one of the following, wherein the low-yield carbon black raw material includes at least one of the following: vegetable oil or other plant-derived oils, bio-derived ethanol, plant or animal waxes or resins, oils obtained from animal fats, algal oil, oils obtained from the thermal decomposition of sewage sludge or agricultural waste, by-product liquids from the processing of bio-based materials, liquids produced by the hydrothermal liquefaction of biomaterials, crude tall oil, tall oil rosin, tall oil pitch or tall oil fatty acids, oils obtained from recycled materials, oils obtained from the thermal decomposition of low-quality tires, defective tires or tires at the end of their lifespan, oils obtained from the thermal decomposition of discarded or recycled plastic or rubber products, oils obtained from the thermal decomposition of municipal solid waste, or oils obtained from the thermal decomposition of biomass, or any combination thereof. (Note 16) The method according to any one of the appendices 1 to 15, wherein the at least first carbon black raw material comprises one or more of decant oil, slurry oil, coal tar, coal tar derivatives, ethylene cracker residue, or phenol cracker residue. (Note 17) The method according to any one of the appendices 1 to 16, wherein the first carbon black raw material is a fraction obtained from the distillation of tire pyrolysis oil. (Note 18) The method according to any one of the appendices 1 to 17, wherein the low yield carbon black raw material is in the range of 50 to 90% by weight of the total raw materials introduced in the method. (Note 19) The method according to any one of the appendices 1 to 18, wherein the low yield carbon black raw material is in the range of 60 to 90% by weight of the total raw materials introduced in the method. (Note 20) The method according to any one of the appendices 1 to 19, wherein the carbon black reactor comprises a first chamber in which the electrically heated is performed, a throat downstream of the first chamber, a reaction chamber downstream of the throat, and a quenching zone downstream of the reaction chamber, and the first carbon black raw material is injected into the throat, and the low yield carbon black raw material is injected after the throat. (Note 21) The method according to Appendix 20, wherein the carbon black reactor comprises a second throat downstream of the reaction chamber and before the quenching zone, and the low-yield carbon black raw material is injected into the second throat. (Note 22) The method according to any one of the appendices 1 to 21, wherein the at least one first carbon black raw material is introduced into the carbon black reactor at the first position and at least one separate position downstream of the first position. (Note 23) The method according to Appendix 22, wherein the amount of the first carbon black raw material introduced at the first position is more than 50% of the total amount of the first carbon black raw material. (Note 24) The method according to any one of the appendices 1 to 23, wherein the at least one low-yield carbon black raw material is introduced into the carbon black reactor at at least two separate locations, one of which is downstream of the other. (Note 25) The method according to any one of the appendices 1 to 24, wherein the at least one first carbon black raw material is a blend containing less than 50% by weight of non-high yield carbon black raw material based on the total weight of the first carbon black raw materials. (Note 26) The method according to any one of the appendices 1 to 25, wherein the at least one first carbon black raw material is a blend containing less than 5% by weight of non-high yield carbon black raw material based on the total weight of the first carbon black raw material. (Note 27) The method according to any one of the appendices 1 to 26, wherein the at least one low-yield carbon black raw material is a blend containing less than 50% by weight of high-yield carbon black raw material based on the total weight of the low-yield carbon black raw material. (Note 28) The method according to any one of the appendices 1 to 27, wherein the at least one low-yield carbon black raw material is a blend containing less than 5% by weight of high-yield carbon black raw material based on the total weight of the low-yield carbon black raw material. (Note 29) The method according to any one of the appendices 1 to 28, wherein the low-yield carbon black raw material has the BMCI of less than 100. (Note 30) The method according to any one of the appendices 1 to 29, wherein the low-yield carbon black raw material has the atomic H:C ratio greater than 1.23. (Note 31) The method according to any one of the appendices 1 to 30, wherein the low-yield carbon black raw material is a gas at room temperature and room pressure. (Note 32) The method according to any one of the appendices 1 to 31, wherein the recovered carbon black is carbon black of grade N110, N121, N220, N231, N234, N299, N326, N330, N339, N347, N351, N358, N375, N539, N550, N650, N660, N683, N762, N765, N774, N787, or N990.

Claims

1. A method for producing carbon black, The method involves electrically heating a carrier gas to form a heated carrier gas, and then contacting the heated carrier gas to cause thermal decomposition of at least a portion of the carbon black raw material within the carbon black reactor, wherein the carbon black raw material comprises at least one first carbon black raw material and at least one low-yield carbon black raw material. The method involves combining the at least one first carbon black raw material with the heated carrier gas to form a reaction flow, wherein the at least one first carbon black raw material constitutes at least 10% by weight of the total carbon black raw material. The carbon black is formed by combining at least one low-yield carbon black raw material downstream of the existing reaction stream, wherein the at least one low-yield carbon black raw material constitutes at least 10% by weight of the total carbon black raw material. To recover the carbon black in the reaction stream, The first carbon black raw material is liquid at room temperature and room pressure, and has the following characteristics: Bureau of Mines Correlation Index (BMCI) 100 or higher, Atomic H:C ratio of 1.23 or less, Specific gravity over 1.02, The low-yield carbon black raw material has the following characteristics: Bureau of Mines Correlation Index (BMCI) less than 100, or Atomic H:C ratio greater than 1.23, or Specific gravity 1.02 or less, Having at least one of the following, It is a gas at room temperature and room pressure. The at least one low-yield carbon black raw material is present in an amount of 10% to 90% by weight based on the total carbon black raw material, and the at least one first carbon black raw material is present in an amount of 10% to 90% by weight based on the total carbon black raw material, A method wherein the carrier gas is electrically heated using an arc, a resistive or inductive heating element, and / or an inductive or microwave-based plasma, and the heated carrier gas has a temperature greater than 2000°C.

2. A method for producing carbon black, The method involves electrically heating a carrier gas to form a heated carrier gas, and then contacting the heated carrier gas to cause thermal decomposition of at least a portion of the carbon black raw material within the carbon black reactor, wherein the carbon black raw material comprises at least one first carbon black raw material and at least one low-yield carbon black raw material. The at least one first carbon black raw material and the at least one low-yield carbon black raw material are combined with the heated carrier gas as a blend or as separate additives, at the same or substantially the same position, to form a reaction flow, wherein the at least one first carbon black raw material constitutes at least 10% by weight of the total carbon black raw material, and the at least one low-yield carbon black raw material constitutes at least 10% by weight of the total carbon black raw material. To recover the carbon black in the reaction stream, The first carbon black raw material is liquid at room temperature and room pressure, and has the following characteristics: Bureau of Mines Correlation Index (BMCI) 100 or higher, Atomic H:C ratio of 1.23 or less, Specific gravity over 1.02, The low-yield carbon black raw material has the following characteristics: Bureau of Mines Correlation Index (BMCI) less than 100, or Atomic H:C ratio greater than 1.23, or Specific gravity 1.02 or less, Having at least one of the following, It is a gas at room temperature and room pressure. The at least one low-yield carbon black raw material is present in an amount of 10% to 90% by weight based on the total carbon black raw material, and the at least one first carbon black raw material is present in an amount of 10% to 90% by weight based on the total carbon black raw material, A method wherein the carrier gas is electrically heated using an arc, a resistive or inductive heating element, and / or an inductive or microwave-based plasma, and the heated carrier gas has a temperature greater than 2000°C.

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

4. The method according to claim 1 or 2, wherein the low-yield carbon black raw material includes at least one of the following: vegetable oil or other plant-derived oils, bio-derived ethanol, plant or animal waxes or resins, oils obtained from animal fats, algal oil, oils obtained from the thermal decomposition of sewage sludge or agricultural waste, by-product liquids from the processing of bio-based materials, liquids produced by the hydrothermal liquefaction of biomaterials, crude tall oil, tall oil rosin, tall oil pitch or tall oil fatty acids, oils obtained from recycled materials, oils obtained from the thermal decomposition of low-quality tires, defective tires or tires at the end of their lifespan, oils obtained from the thermal decomposition of discarded or recycled plastic or rubber products, oils obtained from the thermal decomposition of municipal solid waste, or oils obtained from the thermal decomposition of biomass, or any combination thereof.

5. The method according to claim 1 or 2, wherein the at least first carbon black raw material comprises one or more of the following: decant oil, slurry oil, coal tar, coal tar derivatives, ethylene cracker residue, or phenol cracker residue.

6. The method according to claim 1 or 2, wherein the first carbon black raw material is a fraction obtained from the distillation of tire pyrolysis oil.

7. The method according to claim 1 or 2, wherein the low-yield carbon black raw material is in the range of 50 to 90% by weight of the total raw materials introduced in the method.

8. The method according to claim 1, wherein the carbon black reactor comprises a first chamber in which the electrically heated is performed, a throat downstream of the first chamber, a reaction chamber downstream of the throat, and a quenching zone downstream of the reaction chamber, and the first carbon black raw material is injected into the throat, and the low yield carbon black raw material is injected after the throat.

9. The method according to claim 8, wherein the carbon black reactor comprises a second throat downstream of the reaction chamber and before the quenching zone, and the low-yield carbon black raw material is injected into the second throat.

10. The method according to claim 1 or 2, wherein the at least one first carbon black raw material is introduced into the carbon black reactor at the first position and at least one separate position downstream of the first position.

11. The method according to claim 10, wherein the amount of the first carbon black raw material introduced at the first position is more than 50% of the total amount of the first carbon black raw material.

12. The method according to claim 1 or 2, wherein the at least one low-yield carbon black raw material is introduced into the carbon black reactor at at least two separate locations, one of which is downstream of the other.

13. The method according to claim 1 or 2, wherein the at least one first carbon black raw material is a blend containing a low yield carbon black raw material in an amount of less than 50% by weight based on the total weight of the first carbon black raw materials.

14. The method according to claim 1 or 2, wherein the at least one first carbon black raw material is a blend containing less than 5% by weight of low-yield carbon black raw material based on the total weight of the first carbon black raw materials.

15. The method according to claim 1 or 2, wherein the at least one low-yield carbon black raw material is a blend containing less than 50% by weight of a high-yield carbon black raw material based on the total weight of the low-yield carbon black raw materials.

16. The method according to claim 1 or 2, wherein the at least one low-yield carbon black raw material is a blend containing less than 5% by weight of a high-yield carbon black raw material based on the total weight of the low-yield carbon black raw materials.

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