CN118632905A - Method for producing carbon black from low-yield raw materials using plasma or electric heating process and products prepared therefrom - Google Patents

Abstract

Methods of producing carbon black from low yield carbon black feedstock are described, using processes involving the use of electrical energy to cause the formation of carbon black from carbon black feedstock. Carbon blacks produced from these carbon black feedstocks are further described. The advantages achieved with the method are further described.

Description

Method for producing carbon black from low-yield raw materials using plasma or electric heating process and products prepared therefrom

The present invention relates to methods for producing carbon black from alternative carbon black producing feedstocks, which in many cases may include gaseous and/or low-yielding feedstocks. More specifically, the present invention relates to methods for producing carbon black using plasma or electric heating processes. The present invention further relates to carbon black formed from alternative carbon black producing feedstocks including gaseous and/or low-yielding carbon black feedstocks.

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 compounding and preparation of compositions used in rubber, plastics, paper or textile applications. The properties of carbon black or other fillers are important factors in determining the various performance characteristics of these compositions. An important use of elastomeric compositions relates to the manufacture of tires, and additional ingredients are often added to impart specific properties to the finished product or its components. Carbon black has been used to adjust functional properties, conductivity, rheology, surface properties, viscosity, appearance and other properties in elastomeric compositions and other types of compositions.

The conventional and most common process for the industrial production of carbon black is the furnace process. In this process, a first liquid carbon-bearing feedstock (liquid carbon-bearing feedstock) (e.g., decant oil) is injected into a fuel-depleted gas stream that has been thermally burned or is burning. Some of the feedstock is pyrolyzed to produce carbon black and by-products (mainly hydrogen); the remaining feedstock is oxidized to produce CO, _CO2 , and _H2O . Conventional or traditional feedstocks are decant oil, slurry oil, coker oil, coal tar derivatives, or heavy liquid residues from ethylene cracker processes. These carbon black feedstocks are also heavy (specific gravity>1.02), have an H:C atomic ratio of up to 1.23, are rich in aromatic compounds (Bureau of Mines Correlation Index (BMCI) ≥100), and are liquid at room temperature and pressure (e.g., at 25°C, 1atm). They are generally derived from fossil fuels.

Electric heating carbon black process is an alternative to furnace black process, as 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 carbonaceous feedstock into carbon black particles and byproduct gases. This is in contrast to the furnace method in which partial combustion of the fuel provides this energy. Combustion gases are generated within the carbonaceous feedstock or directly mixed with the carbonaceous feedstock to drive its pyrolysis to carbon black. Although the furnace method dominates the commercial production of carbon black, the electric drive method provides one or more potential advantages over the furnace method.

The electric drive method can use renewable electricity instead of fossil fuel combustion, making the process have a significantly lower greenhouse gas footprint compared to the furnace method. Compared with the furnace method, the carbon black output per unit of raw material consumption of the electric drive method can be higher, thereby saving operating costs. Using electrical energy to supply most or all of the energy required for driving pyrolysis can achieve more control of the gas phase chemical environment in which carbon black is formed. Since energy does not need to come completely from combustion, the chemical environment during particle formation can be made more reducing (as opposed to oxidizing). This provides another method for controlling the final surface chemistry of particles.

Electrically heated carbon black processes tend to use natural gas, ethane or similar gaseous carbonaceous feedstocks as feedstocks for carbon black production, as described, for example, in U.S. Pat. No. 10,100,200. The disadvantage of these gaseous feedstocks is that they tend to produce very low structure for a given surface area. This structure can be too low to meet ASTM grade requirements for rubber reinforcement.

Another disadvantage of electrically heated carbon black processes is that they use a carrier gas. This is done because direct contact of hot, actively heated surfaces (such as those produced at the electrodes) with carbonaceous feedstocks can lead to rapid coke formation and severe operability problems. In addition, many electrode materials can be corroded by hydrocarbon gases at high temperatures during use.

Using a carrier gas such as hydrogen or argon solves both of these problems, but introduces another: the volume of the carrier gas must be larger than the volume of the feedstock. Since high temperatures are required to produce suitable surface area in an aerosol-based carbon black process, this means that as the desired product surface area increases, more and more carrier gas must be used relative to the amount of feedstock. Increasing the carrier gas volume significantly increases capital costs.

In existing carbon black processes, using gaseous, renewable, recycled and/or sustainable low-yield raw materials will be economically useful and environmentally beneficial. These raw materials need not be based on fossil fuels. Examples of these include ethylene, which can be produced by ethane cracking or by bioethanol. Another example is natural gas, which can be based on fossils or produced by the decay of landfill or organic matter. Other examples include vegetable oil, derived from the pyrolysis of recycled tires, plastics, municipal waste or biomass, or the natural gas produced by landfill.

Unfortunately, these low-yield carbon black feedstocks typically produce poor yields, low surface areas, and/or low structures in the carbon black process compared to conventionally used carbon black feedstocks. The performance of these feedstocks in the electrically heated carbon black process can be so poor that it is impossible to produce the structures required for most ASTM grades with them. The maximum achievable structure of a feedstock at a given surface area helps to define the gradeability of the feedstock.

Therefore, the industry needs to provide a solution that can use an electrically heated carbon black process, which can greatly improve the structure of the produced carbon black.

Additionally, there is a need in the industry to provide a solution that reduces capital costs by achieving a given surface area at lower reaction temperatures for electrically heated carbon black processes.

Furthermore, there is a need in the industry to provide a solution that enables (allows the use of) various amounts of low-yield carbon black forming feedstocks in existing electrically heated carbon black processes and still produces carbon blacks comparable to carbon blacks formed from conventional carbon black feedstocks (e.g., produces carbon blacks with acceptable yields and/or with high surface area and/or high structure). Using existing electrically heated carbon black processes to use these low-yield feedstocks rather than developing, designing, and building new processes for using them saves significant capital and development resources.

All patents and publications mentioned throughout are incorporated herein by reference in their entirety.

Summary of the invention

A feature of the present invention is to provide a method for preparing or producing carbon black from a feedstock including a low-yielding carbon black feedstock.

It is a further feature of the present invention to provide a method for preparing or producing carbon black from a feedstock comprising a gaseous carbon black feedstock.

A further feature of the present invention is to provide a method for preparing or producing carbon black using an electrically heated carbon black process and to greatly improve the structure of the produced carbon black.

In addition, a feature of the present invention is to provide a method for preparing or producing carbon black using an electrically heated carbon black process and to reduce investment costs by obtaining a given surface area at a lower reaction temperature for the electrically heated carbon black process.

Another feature of the present invention is to provide carbon black prepared from a feedstock including a low-yielding carbon black feedstock.

Another feature of the present invention is to provide carbon black prepared from a feedstock including a gaseous carbon black feedstock.

Another feature is to provide a method of utilizing a carbon black feedstock wherein at least a portion, or more, of the total amount of feedstock is a low-yielding carbon black feedstock.

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

To achieve these and other advantages, and in accordance with the purposes of the present invention, as embodied and broadly described herein, the present invention relates in part to a method for producing carbon black. The method includes the step of electrically heating a carrier gas or a carbon black feedstock or both to cause pyrolysis of at least a portion of the carbon black feedstock. The carbon black feedstock comprises at least one first carbon black feedstock and at least one low-yield carbon black feedstock. In one method of the present invention, the first carbon black feedstock is first contacted with a heated carrier gas formed by electrically heating the carrier gas to form a reaction stream, and then the low-yield carbon black feedstock is mixed with the existing reaction stream downstream to form carbon black. The method further includes collecting the carbon black in the reaction stream. In the method, at least one low-yield carbon black feedstock preferably accounts for at least 10% by weight of the total feedstock and no more than 90% by weight of the total feedstock (based on the total weight).

In addition, the present invention relates in part to another method for producing carbon black. The method includes electrically heating a carrier gas or a carbon black feedstock or both to cause the step of pyrolysis of at least a portion of the carbon black feedstock. The carbon black feedstock comprises at least one first carbon black feedstock and at least one low-yield carbon black feedstock. In the method of the present invention, the first carbon black feedstock and the low-yield carbon black feedstock are contacted with a heated carrier gas formed by electrically heating the carrier gas to form a reaction stream and form carbon black. At least one first carbon black feedstock and at least one low-yield carbon black feedstock can be in the form of a blend, or can be introduced separately at the same or approximately the same position. The method further includes collecting the carbon black in the reaction stream. In the method, at least one low-yield carbon black feedstock preferably accounts for at least 10% by weight of all raw materials and no more than 90% by weight of all raw materials (based on total weight).

Additionally, the present invention relates in part to carbon black wherein at least 10 weight percent of the feedstock used to form the carbon black is at least one low-yielding carbon black feedstock and at least 10 weight percent of the feedstock used to form the carbon black is at least one carbon black feedstock.

The present invention also relates to products and/or articles, such as, but not limited to, elastomeric composites formed from any one or more of the carbon blacks of the present invention.

It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are intended to provide further explanation of the invention as claimed.

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

BRIEF DESCRIPTION OF THE DRAWINGS

1 is a graph showing the H:C (hydrogen atoms to carbon atoms) atomic ratio of conventional carbon black feedstocks compared to low-yield feedstocks used in part in the present invention.

2 is a graph showing the specific gravity of conventional carbon black feedstocks compared to low-yielding feedstocks used in part in the present invention.

3 is a graph showing BMCI values for conventional feedstocks compared to low-yielding feedstocks used in part in the present invention.

FIG. 4 is a cross-sectional view of one example of a reactor suitable for preparing the carbon black of the present invention.

FIG5 is a cross-sectional view of another example of a reactor suitable for preparing the carbon black of the present invention.

FIG. 6 is a cross-sectional view of another example of a reactor suitable for preparing the carbon black of the present invention.

DETAILED DESCRIPTION

The present invention relates to a method for producing carbon black, the method utilizing a low-yielding carbon black feedstock as defined and described herein, and utilizing an electrically heated carbon black process. The present invention also relates to carbon black prepared by one or more of these methods. Using the method of the present invention, a portion of the total carbon black feedstock used can be one or more low-yielding carbon black feedstocks. Using the method of the present invention, not only can small to large amounts of low-yielding carbon black feedstocks be used, but the quality of the carbon black produced will not be sacrificed. Therefore, the method of the present invention utilizes carbon black feedstocks that are more desirable for environmental reasons and/or other reasons, and also produces carbon black that is comparable to carbon black produced using traditional carbon black feedstocks used in furnace black processes and/or traditional plasma processes.

The method for producing carbon black of the present invention comprises the following steps, consists essentially of the following steps, consists of the following steps or includes the following steps: 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; combining at least one low-yielding carbon black raw material into the existing reaction stream downstream to form carbon black, and recovering the carbon black in the reaction stream. In this method, preferably, at least one low-yielding carbon black raw material accounts for at least 10% by weight of the total raw materials, and may more preferably account for at least 25% by weight of the total raw materials, or at least 50% by weight of the total raw materials, or at least 60% by weight of the total raw materials, and the first carbon black raw material accounts for at least 10% by weight of the total raw materials.

Another method of the present invention comprises the following steps, consists essentially of the following steps, consists of the following steps or includes the following steps: a carbon black raw material comprising, consisting essentially of, consisting of or including the following is combined with an electrically heated gas stream (or an electrically heated carrier gas stream) to form a reaction stream to form carbon black, and the carbon black in the reaction stream is recovered: at least one first carbon black raw material and at least one low-yield carbon black. The carbon black raw material can be introduced as a blend, or a plurality of separate carbon black raw materials can be introduced (e.g., at the same position or approximately the same position) and combined with the electrically heated gas stream. In this method, preferably, at least one low-yield carbon black raw material accounts for at least 10% by weight of the total raw materials, and can more preferably account for at least 25% by weight of the total raw materials or at least 50% by weight of the total raw materials, and the first carbon black raw material accounts for at least 10% by weight of the total raw materials.

For purposes of the present invention, a "low-yielding carbon black feedstock" is a carbon black feedstock having at least one of the following properties:

1) a Bureau of Mines Correlation Index (BMCI) < 100 (which provides an indication of low aromatics content of the liquid feed) (e.g., a BMCI of less than 99, less than 95, less than 90, less than 85, less than 80, less than 75, less than 70, e.g., a BMCI of 50 to 99 or 60 to 99, or 70 to 99, or 50 to 95 or 50 to 90), and/or

2) a carbonaceous material that is gaseous at room temperature (e.g., 25°C) and pressure (1 atm), and/or

3) an H:C atomic ratio greater than 1.23 (e.g., an H:C ratio of 1.24 or greater, 1.25 or greater, 1.26 or greater, 1.27 or greater, 1.28 or greater, 1.29 or greater, 1.30 or greater, 1.35 or greater, 1.40 or greater, 1.45 or greater, 1.50 or greater, e.g., 1.235 to 1.5, or 1.235 to 1.45 , or 1.235 to 1.4, or 1.235 to 1.35, or 1.235 to 1.3, or 1.235 to 1.29, or 1.235 to 1.28, or 1.235 to 1.27, or 1.24 to 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) a specific gravity of at most 1.02 (e.g., at most 1.015, at most 1.01, at most 1.005, at most 1.01, at most 1.00, at most 0.99, at most 0.95, e.g., 0.80 to 1.019, or 0.80 to 1.015, or 0.80 to 1.01, or 0.80 to 1.005, or 0.80 to 1.00, or 0.80 to 0.95, or 0.80 to 0.9, or 0.80 to 1.015, or 0.90 to 1.01, or 0.90 to 1.005, or 1.005 to 1.015).

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

The low-yielding carbon black feedstock may have a BMCI nature and an atomic H:C nature.

The low yield carbon black feedstock may have BMCI properties and specific gravity properties.

The low-yielding carbon black feedstock may have BMCI properties and gas properties.

The low-yielding carbon black feedstock may have BMCI properties, atomic H:C properties, and specific gravity properties.

The low-yielding carbon black feedstock may have a BMCI nature, an atomic H:C nature, and a gas nature.

The low-yielding carbon black feedstock may have BMCI properties, atomic H:C properties, specific gravity properties, and gas properties.

The low yield carbon black feedstock may have atomic H:C properties and specific gravity properties.

The low-yielding carbon black feedstock may be of atomic H:C nature and of gaseous nature.

The low-yielding carbon black feedstock may have atomic H:C properties, specific gravity properties, and gas properties.

The low-yielding carbon black feedstock may have a specific gravity property and a gaseous property.

Low-yield carbon black feedstock can be a feedstock derived from a source that is considered to be sustainable, biological and/or recycled. For example, low-yield carbon black feedstock can be or include ethylene (a gas at room temperature and pressure). Ethylene can be produced by ethanol from biological sources, such as by fermentation of corn or other plant materials. Another example of low-yield carbon black feedstock is natural gas.

For the purposes of the present invention, a low-yielding carbon black feedstock can be a feedstock that is not derived from fossil fuel-based gasoline production or coal cracking or cracking to produce olefins. Thus, a low-yielding carbon black feedstock is a feedstock other than coal tar liquids, refinery liquids, or ethylene cracker residues.

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

Table 1

Label H I J K L Raw material examples Bolder350 tire pyrolysis oil Delta Energy Green Tire Pyrolysis Oil Soybean Oil Corn Oil Peanut Oil Data Source e f g h、i h、i Atomic H:C 1.32 1.50 1.87 1.87 1.87 proportion 1.00 0.94 0.93 0.92 0.91 BMCI 94 62.5 56 54 50 Sulfur content (weight %) 1.08 1.03 0 0 0 Flash point(℃) 68 32 >110 321 315

Figure 1 is a graph presenting the H:C atomic ratio of a traditional high-yield carbon black feedstock compared to tire pyrolysis oil (TPO), vegetable oil (Veg.Oil) and two gaseous feedstocks (natural gas and ethylene) (gas). For traditional feedstocks, the H:C of a collection of approximately 1,000 representative coal tar liquids, decant oils, and ECRs used as carbon black feedstocks for furnace black processes was plotted between 2016 and 2021. The range of H:C values can be compared to three low-yield carbon black feedstock groups. Obviously, the traditional feedstock has a low H:C value of ≤1.23 (dashed line in the figure). The low-yield carbon black feedstocks in Figure 1 all have H:C values of>1.23.

FIG. 2 is a graph presenting an example of the specific gravity of a conventional high-yield feedstock compared to tire pyrolysis oil (TPO) and vegetable oil (Veg.Oil). For conventional feedstocks, the specific gravity of a collection of approximately 1,000 representative coal tar liquids, decant oils, and ECRs used as carbon black feedstocks for furnace black processes was plotted between 2016 and 2021. The specific gravity range is compared to two low-yield carbon black feedstock groups. Clearly, conventional feedstocks typically have a specific gravity greater than 1.02 (dashed line in the graph), while low-yield carbon black feedstocks have a specific gravity of 1.02 or less.

Figure 3 is a graph presenting examples of BMCI numbers for traditional high-yield raw materials compared to tire pyrolysis oil (TPO) and vegetable oil (Veg.Oil). For traditional carbon black raw materials, BMCI numbers were plotted for a collection of approximately 1,000 representative coal tar liquids, decant oils, and ECRs used as raw materials for furnace black processes between 2016 and 2021. Their BMCI values were compared to two low-yield raw material groups. Almost all traditional raw materials have BMCI values > 110, and all examples shown here have BMCI numbers greater than or equal to 100 (dashed lines). In contrast, the BMCI numbers for the TPO and vegetable oil groups are less than 100.

Other examples of low-yield carbon black feedstocks may include, but are not limited to, the following: renewable feedstocks, bio-derived or bio-based feedstocks and/or other byproducts of refining processes, or any combination thereof.

Other examples of low-yielding carbon black feedstocks may include, but are not limited to, the following: vegetable or other plant-derived oils (eg, corn oil and/or corn distillates).

Other examples of low-yielding carbon black feedstocks may include, but are not limited to, the following: bio-derived ethanol (from corn fermentation or other plant, vegetable or fruit derived fermentation products).

Other examples of low-yielding carbon black feedstocks may include, but are not limited to, the following: plant or animal produced waxes and resins, such as lanolin or shellac.

Other examples of low-yielding carbon black feedstocks may include, but are not limited to, the following: oils made from animal fats.

Other examples of low-yielding carbon black feedstocks may include, but are not limited to, the following: algae oil.

Other examples of low-yielding carbon black feedstocks may include, but are not limited to, the following: oils produced from pyrolysis of sewage sludge or agricultural waste.

Other examples of low-yielding carbon black feedstocks may include, but are not limited to, the following: byproduct liquids from the processing of biogenic materials.

Other examples of low-yielding carbon black feedstocks may include, but are not limited to, the following: liquids produced by hydrothermal liquefaction of biomass.

Other examples of low-yielding carbon black feedstocks may include, but are not limited to, the following: crude tall oil, tall oil rosin, tall oil pitch, or tall oil fatty acid (eg, from a papermaking process).

Other examples of low-yielding carbon black feedstocks may include, but are not limited to, the following: renewable feedstocks, such as oils produced from recycled materials.

Other examples of low-yielding carbon black feedstocks may include, but are not limited to, the following: oils derived from the pyrolysis of low-quality, off-spec, or scrap tires.

Other examples of low-yielding carbon black feedstocks may include, but are not limited to, the following: oils derived from the pyrolysis of waste or recycled plastics.

Other examples of low-yielding carbon black feedstocks may include, but are not limited to, the following: oils derived from pyrolysis of municipal solid waste.

Other examples of low-yield carbon black feedstocks may include, but are not limited to, the following: oils derived from the pyrolysis of biomass (bio-oils), such as animals or plants (eg, vegetables).

As described above, in the present invention, a portion (in terms of weight %) of the total feedstock used in the process of the present invention (in a staged process or introduced as a blend or introduced at the same position or approximately the same position in the reactor) is one or more low-yielding carbon black feedstocks, and a portion is not a low-yielding carbon black feedstock.

For purposes of the present invention, "approximately the same location" means that the introduction of the multiple feedstocks occurs at the same location (I ₁ ) or does not deviate from I ₁ by more than 5% based on the entire length of the carbon black reactor.

Preferably, the amount of low-yielding carbon black feedstock (introduced in a staged process or as a blend or at the same location or about the same location as one or more other carbon black feedstocks) is at least 10 wt%, or at least 15 wt%, or at least 20 wt%, or at least 25 wt%, or at least 30 wt%, or at least 35 wt%, or at least 40 wt%, or at least 45 wt%, or at least 50 wt%, or at least 55 wt%, or at least 60 wt%, or at least 65 wt%, or at least 70 wt%, or at least 75 wt%, or at least 80 wt%, or at least 85 wt%, or at least 90 wt%, but less than 100 wt% and preferably less than 99 wt% or less than 95 wt%, for example from 10 wt% to 95 wt%, or from 10 wt% to 90 wt%, or from 15 wt% to 90 wt%, or from 20 wt% to 90 wt%, % to 90 wt %, or 30 wt % to 90 wt %, or 35 wt % to 90 wt %, or 40 wt % to 90 wt %, or 45 wt % to 90 wt %, or 50 wt % to 95 wt %, or 10 wt % to 80 wt %, or 10 wt % to 70 wt %, or 10 wt % to 60 wt %, or 10 wt % to 50 wt %, or 10 wt % to 40 wt %, or 10 wt % to 30 wt %, or 60 wt % to 95 wt %, or 65 wt % to 95 wt %, or 70 wt % to 95 wt %, or 75 wt % to 95 wt %, or 60 wt % to 95 wt %, or 60 wt % to 90 wt %, or 60 wt % to 85 wt %, or 60 wt % to 80 wt %, or 60 wt % to 75 wt %, based on the total weight percentages of all raw materials used.

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

The first carbon black feedstock is typically from the family of decant or slurry oils, coal tar or coal tar distillate fractions, or ethylene or phenol cracker residues. Their limiting characteristics relative to carbon black production in a typical furnace process are discussed further below.

The first carbon black feedstock has all three of the following properties:

1) a BMCI of at least 100 (e.g., at least 101, at least 102, at least 103, at least 104, at least 105, at least 110, at least 115, at least 120, at least 130, at least 140, at least 150, at least 160, at least 170, such as 100 to 180, 101 to 180, 102 to 180, 103 to 180, 104 to 1 80, 105 to 180, 110 to 180, 115 to 180, 120 to 180, 130 to 180, 140 to 180, 150 to 180, 160 to 180, 100 to 175, 100 to 170, 100 to 165, 110 to 175, 115 to 175, 120 to 175, 125 to 170, 130 to 170),

2) a specific gravity greater than 1.02 (e.g., greater than 1.025, greater than 1.03, greater than 1.035, greater than 1.04, greater than 1.05, such as 1.021 to 1.3, or 1.025 to 1.3, or 1.03 to 1.3, or 1.05 to 1.3, or 1.07 to 1.25),

3) an H:C atomic ratio of at most 1.23 (e.g., at most 1.22, at most 1.21, at most 1.2, at most 1.15, at most 1.1, at most 1.05, at most 1, at most 0.9, at most 0.8, e.g., 1.225 to 0.7, 1.225 to 0.8, 1.225 to 0.9, 1.225 to 1, 1.225 to 1.1, 1.22 to 0.7, 1.21 to 0.7, 1.2 to 0.7).

Alternatively, the first carbon black feedstock may also be a liquid at the temperature and pressure in the chamber (eg, 25° C. and 1 atm). Although liquid, the first carbon black feedstock may be pitch or a similar material having a very high viscosity and need not exhibit significant flow.

Examples of the first carbon black feedstock are given in Table 2 below, and include coal tar, liquid distilled from coal tar, decanted or slurry oil obtained from catalytic cracking, and residual oil from ethylene cracking. As shown in Table 2, these feedstocks have an H:C of at most 1.23, a specific gravity of greater than 1.02, and a BMCI value of at least 100.

Table 2

Label A B C D E F G Raw material examples Ethylene Steam Cracker Residues Ethylene Steam Cracker Residues Decanting oil Decanting oil Coal tar distillates Crude coal tar Decanting oil Data Source a b a c a d e Atomic H:C 0.94 0.91 0.94 1.01 0.85 0.72 1.01 proportion 1.07 1.08 1.10 1.11 1.14 1.22 1.10 BMCI 127 146 132 134 161 179 163 Sulfur content (weight %) 0.2 0.17 2.1 0.95 0.6 0.38 1.36 Flash point(℃) 70 86 130 90 90

The first carbon black feedstock may also include a fraction derived from refining or distilling tire pyrolysis oil. Exemplary methods include, but are not limited to, those found in US8350105 and US20180320082, the entire contents of which are incorporated herein by reference. The distillation of the resulting oil may also be accomplished by any method known to those skilled in the art. Exemplary methods include, but are not limited to, those found in US9920262, WO2019236214, the contents of which are incorporated herein by reference. Tire pyrolysis oil may be distilled to provide at least one fraction that may be used as the first carbon black feedstock and at least one fraction as a low-yield carbon black feedstock. In fact, distillation may produce a light fraction that may be more economically used in other unit processes of the carbon black production process, for example, as a fuel for a dryer for carbon black or a fuel for preheating a heater for either or both of the first carbon black feedstock or the second carbon black feedstock, as disclosed in US20130039841, the contents of which are incorporated herein by reference. Therefore, integration of the distillation process with the carbon black reactor can achieve economic and environmental benefits from the recycling of carbon black-filled tires.

Alternatively, in the process of the present invention, based on the total amount of raw materials used (in weight %), the first carbon black raw material may be at least 10 weight %, or at least 15 weight %, or at least 20 weight %, or at least 25 weight %, or at least 30 weight %, or at least 35 weight %, or at least 40 weight %, or at least 45 weight %, or at least 50 weight %, or at least 55 weight %, or at least 60 weight %, or at least 65 weight %, or at least 70 weight %, or at least 75 weight %, or at least 80 weight %, or at least 85 weight %, or at least 90 weight %, but less than 100 weight % and preferably less than 99 weight % or less than 95 weight %, for example, 10 weight % to 95 weight %, or 10 weight % to 90 weight %, or 15 weight % to 90 weight %, or 20 weight % to 90 weight %, or 25 weight % to 90 weight %, or 30 weight % to 90 weight %, % to 95 wt%, or 65 wt% to 95 wt%, or 70 wt% to 95 wt%, or 75 wt% to 95 wt%, or 60 wt% to 95 wt%, or 60 wt% to 90 wt%, or 60 wt% to 85 wt%, or 60 wt% to 80 wt%, or 60 wt% to 75 wt% (introduced in a fractionation process or as a blend or introduced at the same location or about the same location as one or more other carbon black feedstocks). Other amounts of the first carbon black feedstock may be 49 wt % or less, 45 wt % or less, 40 wt % or less, 35 wt % or less, 30 wt % or less, 25 wt % or less, 20 wt % or less, 15 wt % or less, 10 wt % or less, 9 wt % or less, 8 wt % or less, 7 wt % or less, 6 wt % or less, such as 5 to 49 wt % or 5 to 45 wt % or 10 to 40 wt %, or 10 to 35 wt %, or 10 to 30 wt %, based on the total amount of feedstock used (in wt %).

The first carbon black feedstock can be a liquid at room temperature (e.g., 25° C.) and atmospheric (e.g., 1 atm) conditions. "Rich in aromatics" means that the feedstock has a large amount of aromatic compounds present. For example, a large amount of aromatic compounds is one in which the total weight percentage of aromatic compounds present is at least 20 weight percent or has a BMCI of at least 100, or both. The first carbon black feedstock can be heated so that the feedstock is in vapor form and can therefore become an aromatic-rich vapor or be used as an aromatic-rich vapor in practice.

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

In other methods of the present invention, the carbon black feedstock or a portion thereof is electrically heated to cause pyrolysis of the feedstock.

In the process of the present invention, electrical heating of the carrier gas and/or carbon black feedstock may be such that the electrical heating is direct or indirect (eg, direct means that a heating element contacts the carrier gas and/or feedstock).

To generate the electrically heated gas stream, at least four methods can be used for the purpose of the present invention. In any method, electrical energy is used to heat the carrier gas and/or the carbon black feedstock, so that at least a portion of the carbon black feedstock undergoes pyrolysis.

The invention can be practiced in several variations or embodiments.

In the first method, an electric arc can be used to electrically heat a carrier gas which is then contacted with the carbon black feedstock as described herein. When the electric arc produces a plasma, the method is sometimes referred to as a plasma process.

In the second method, a resistance or induction based heating element is used to electrically heat the carrier gas which is then contacted with the carbon black feedstock as described herein.

In the third method, an induction or microwave-based plasma is used to heat the carrier gas or the carbon black feedstock itself without direct contact between the gas and the electrodes.

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

Methods for forming or generating electrically heated gas streams and/or carbon black feedstocks and equipment/apparatus and conditions/parameters for doing so are commercially available and may be adapted or used herein for the present methods.

In more detail, and simply as an example, examples of the first method (plasma process using a carrier gas) and the second method (electric heating process using a carrier gas) are described in further detail.

Plasma processes can be used to produce carbon black by heating a suitable carrier gas stream to a high temperature so that the carbon black feedstock can be pyrolyzed when combined with an electrically heated carrier gas stream (e.g., 3000° C. or higher). Heating can be achieved with an electric arc. Once a heated carrier gas stream is formed, the carbon black feedstock can be introduced into or combined with the heated carrier gas stream. The hot carrier gas stream contains most of the energy required to drive the rapid high-temperature pyrolysis of the feedstock into carbon black and byproduct gases. Further details of the process that can be used in the method of the present invention are set forth in U.S. Patent No. 9,574,086 (the entire contents of which are incorporated herein by reference).

An example of an apparatus 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 having a diameter 5, for example, via a conduit 2. The bulk flow of material is in direction A. An electrode 3 generates an arc 4, which heats the carrier gas, typically to plasma conditions.

The heated carrier gas is then combined or mixed with a carbon black feedstock, which may 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 FIG. 4 , injector 8 is depicted as being downstream of injector 7 at throat 9 having the narrowest diameter of carbon black reactor 10. Alternatively, injector 8 may be positioned downstream of injector 7, but in an area having a wider diameter than throat 9. For example, injector 7 may introduce or inject a first carbon black feedstock into the reactor, and additional carbon black feedstock, such as a low-yield carbon black feedstock, may be introduced at injection point 8. The distance between injectors 7 and 8 only needs to be long enough to mix the first carbon black feedstock injected into reactor 10 at injector 7 into the carrier gas. In the present invention, typically, at least a portion (if not all) of the first carbon black feedstock may be injected or introduced at least before the low-yield carbon black feedstock is introduced into the reactor. Preferably, most of the first carbon black feedstock is introduced before any low-yield carbon black feedstock is introduced. To aid in this mixing process, the hot carrier gas may be forced into the narrower throat 9 to increase turbulence and produce rapid mixing. Since the first carbon black feedstock is typically injected as a liquid, the increased turbulence created by the contraction may also aid in atomization of the droplets.

After injection of the first and low carbon black yielding feedstocks, the combined flow of hot carrier gas and reaction feedstocks enters a suitable reaction chamber 14 having a diameter 11. Diameter 11, as well as diameter 5, may be substantially greater than the diameter of throat 9. At some location 12 downstream of the final feedstock injection point, the mixture is quenched using a gas or liquid spray 13.

The throat 9 in Figure 4 may be optional and not used. Alternatively, a single injection point (e.g., injection point 7 or injection point 8) may be used, where the first and low-yielding carbon black feedstocks are introduced as a blend. As another option, more than the two feedstock injection points shown in 7 and 8 may be used.

The plasma heating apparatus in FIG. 4 may be replaced in whole or in part by a system 15 made of resistive heating wires or inductive heating elements, as shown in FIG. 5 , which depicts a cross-section of another reactor 15. The method and apparatus are similar to those in FIG. 4 , except that the carrier gas is now heated separately from the arc that produces the plasma. FIG. 5 depicts a set of resistive heating elements 16 (e.g., rods) positioned in the path of the carrier gas, which is introduced through a conduit (not shown) in a manner similar to the apparatus of FIG. 4 . In FIG. 5 , the resistive 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 described in conjunction with FIG. 4 . Alternatively or additionally, ceramic heating elements may be employed, such as magnesium oxide or zirconium oxide stabilized with yttria.

The elements 16 may be heated by subjecting them to an electric current passing therethrough, or may be inductively heated, for example, by subjecting them to microwave, radio frequency or other suitable electromagnetic radiation. As is known in the art, the electromagnetic energy in the microwave radiation causes electrons to move in the rods, heating them. This approach allows the reactor to have no direct penetration for electrical connections, which may be beneficial in certain circumstances. For example, SiC rods will heat up when subjected to microwave radiation. In this embodiment, there is no need to pass wires or other conductors into the heating chamber, thereby reducing design complexity.

The method of the present invention can be applied to an electric heating process and reactor as shown in FIG6 . FIG6 shows a cross section of another example of a carbon black reactor 20 having features similar to the device 10 of FIG4 . In contrast to FIG4 , the reactor 20 is characterized by having two contracting throats 64 and 65 with narrowed diameters at either end of the intermediate chamber 58. The hot carrier gas from the conduit 2 is fed toward the contracting throat 64. The first carbon black feedstock is fed through the injector 7 or 8, or through both the injectors 7 and 8, and mixed with the carrier gas.

In FIG6 , the length between the introduction of the carrier gas and the middle of the contraction 64 is marked as length 60. The length may preferably be 1X (times) to 10X the narrowest diameter of the first contraction 64. Adjusting the length may allow for balancing carbon black structure and process economics. The height or diameter 5 of the heated gas chamber is shown, and the height is greater than the height or diameter 64. The height or diameter 64 may be at least 20%, at least 30%, at least 40%, at least 50% smaller than the height or diameter 5.

After the first carbon black feedstock is introduced, the hot gas stream mixed with the feedstock enters the first reaction chamber 58. The purpose of this chamber is to provide residence time so that the pyrolysis reaction that produces carbon black can complete the induction time and begin, and optionally, to produce a seed particle population for later structural growth. The length of this chamber 66 can typically be 1X to 20X the narrowest diameter of the first contraction 64.

At the end of the first reaction chamber 58, a low-yielding carbon black feedstock may be introduced. It may be introduced using an injector or injector array 59 located within or near the second contraction 65 and/or substantially downstream of the first locations 7 and/or 8. Alternatively, the low-yielding carbon black feedstock may be introduced using a spray gun substantially upstream of the contraction 65 but within the chamber 58.

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

After the low-yielding carbon black feedstock is introduced, the mixture flows into the 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-yielding carbon black feedstock to the quenching location 62 is marked as 67 in Figure 6. This length is set to provide a residence time that controls certain product properties as is known in the art.

Another arrangement introduces the first carbon black raw material at position 7 and/or position 8, and then introduces the low-yield carbon black raw material at position 8 and/or 59 (and/or a position between these positions), and if two positions are used, they can be introduced simultaneously. This can provide a beneficial trade-off between structural capacity and output or process economy. In all of the above embodiments, at least a portion of the first carbon black raw material used, preferably a majority, such as all of the first carbon black raw material, is introduced before and upstream of the low-yield carbon black raw material.

Utilizing the present invention, the process allows vapor phase carbon black feedstocks or other non-traditional low yielding carbon black feedstocks to produce larger carbon black structures than can be achieved in conventional processes where non-traditional carbon black feedstocks can be used.

Furthermore, with the present invention, the temperature required to produce a given surface area can be reduced compared to using exclusively non-traditional feedstocks. This means that less carrier gas is required, reducing capital costs in the electrically heated process. For example, the temperature can be reduced by 2% to 5% or more.

For example, the injector 7 can introduce or inject the first carbon black feedstock into the reactor. As an alternative, an axial tube or a spray gun can also be used to introduce the first carbon black feedstock into the chamber. As another alternative, the first carbon black feedstock can be injected or introduced simultaneously by a variety of methods. The spray gun or any other injector exposed to the reactor may need to be cooled or prevented from overheating in the reactor by methods known in the art.

In the present invention, as an option, at least a portion (if not all) of the first carbon black feedstock can be injected or introduced before the low-yield carbon black feedstock is introduced into the reactor. Preferably, the amount of the first carbon black feedstock injected or introduced into the reactor before the introduction of the low-yield carbon black feedstock is greater than the total amount of the first carbon black feedstock introduced in any subsequent stage. That is, most of the first carbon black feedstock used in the reactor (>50%) is introduced or injected in the first stage (e.g., at position/injector 7 in Figure 4).

The carbon black feedstock can be injected into the heated carrier gas stream through one or more nozzles, which are designed to optimally distribute the feedstock into the gas stream. Such nozzles can be single-fluid or dual-fluid. The dual-fluid nozzle can use, for example, steam, air or nitrogen to atomize the feedstock. The single-fluid nozzle can be pressure-atomized, or the feedstock can be directly injected into the gas stream. In the latter case, atomization occurs by the force of the gas stream.

The carbon black feedstock can be injected through an axial injection lance, or a central tube and/or one or more radial lances arranged on the circumference of the reactor in a plane perpendicular to the flow direction can be used. The reactor can contain several planes with radial lances along the flow direction. Spray or injection nozzles can be arranged on the head of the lance, through which the feedstock is mixed into the stream of the heated gas stream.

The first carbon black feedstock can be introduced at one or more locations, or at two locations simultaneously, or at three or more locations simultaneously. When more than one location is used among these locations, the manner and division of the first feedstock injection can be varied to alter product properties and process economics. The injector and the reactor chamber (or portions thereof) can be cooled as desired by methods known in the art.

In another example of the present invention, the first carbon black raw material can be a blend of a high-yield carbon black raw material and a low-yield carbon black raw material that meet the above-mentioned BMCI, specific gravity and H: C parameters, provided that the blend meets the above-mentioned BMCI, specific gravity and H: C parameters of the first carbon black raw material. The blend can contain more than 50% by weight of the high-yield carbon black raw material (e.g., 50.5% to 99.5% by weight of the high-yield carbon black raw material, such as 60% to 99% by weight).

Similarly, the low-yielding carbon black feedstock may optionally be a blend of a high-yielding carbon black feedstock and a non-high-yielding carbon black feedstock that fails to meet at least one of the BMCI, H:C, and specific gravity parameters required for the first carbon black feedstock, provided that the blend also fails to meet at least one of the BMCI, H:C, and specific gravity parameters required for the first carbon black feedstock. The non-high-yielding carbon black feedstock may be present in an amount greater than 50% by mass of the total feedstock of the optional blend (e.g., 50.5 wt % to 99.5 wt %, such as 60 wt % to 99 wt %, of the non-high-yielding carbon black feedstock).

In addition, as an option, the total amount of the first carbon black feedstock introduced into the reactor through the sum of all injection locations can be less than 50% by weight of the total amount of carbon black feedstock used anywhere in the reactor. The total amount of low-yielding carbon black feedstock can be greater than 50% by weight based on all feedstocks.

Alternatively, in a method of the present invention, the method includes the step of introducing at least one first carbon black raw material into a carbon black reactor together with a heated gas stream to form a reaction stream. The first carbon black raw material can be a combination of one or two or more different first carbon black raw materials. When more than one type of raw material is used as the first carbon black raw material, the multiple first carbon black raw materials can be blended together and injected as a blended raw material through one or more locations, or each raw material can be injected into the reactor separately at the same or different locations.

Alternatively, in a method of the present invention, the method includes the step of introducing at least one low-yield carbon black raw material into the reaction stream. The low-yield carbon black raw material can be a combination of one or two or more different low-yield carbon black raw materials. When more than one type of raw material is used as the low-yield carbon black raw material, a plurality of low-yield carbon black raw materials can be blended together and injected as a blended raw material through one or more positions, or each raw material can be injected into the reactor separately at the same or different positions.

Typically, any carbon black feedstock used in any method of the present invention can be injected into the reactor using a syringe through a single stream or multiple streams, and the syringe penetrates into the internal area of the heated gas stream. The syringe can better ensure high-speed mixing and shearing of the heated gas stream and the carbon black feedstock. This ensures that the feedstock is pyrolyzed and preferably pyrolyzed quickly and/or in high yield to form the carbon black of the present invention.

The first carbon black feedstock can be introduced at one position in the reactor or at multiple positions in the reactor. In one embodiment of the invention, the low-yield carbon black feedstock can be introduced at one position in the reactor or at multiple positions in the reactor. As noted, in this method of the present invention, one or more positions in the reactor can be downstream of the one or more positions where the first carbon black feedstock is injected or introduced. The introduction of the low-yield carbon black feedstock can be carried out with one or more injectors (e.g., metal tubes located on the reactor wall), which introduce the feedstock into the reactor. The injector can have an injector head or a nozzle on the end. The injector on the end can have, for example, one or more holes (2 or 3 or 4 or more) (usually multiple holes evenly spaced) around the end.

Alternatively, the low carbon black yielding feedstock can be introduced into the reactor and reaction stream such that the feedstock is introduced perpendicular to the lateral flow of the reaction stream through the reactor, such as shown in Figures 4-6. Perpendicular can be plus or minus 15 degrees of true vertical injection of the feedstock into the reaction stream.

As an option, the low-yielding carbon black feedstock can be introduced into the reactor at a location where the diameter is narrower than the diameter of the reactor where the first carbon black feedstock was introduced earlier. For example, injector 8 in FIG. 4 is in a narrower portion of reactor 10 than injector 7. In some carbon black reactors, this location can be considered the "throat". The narrower diameter can have a diameter that is at least 10% smaller, at least 20% smaller, or at least 30% smaller, or 10% to 40% smaller than the diameter of the reactor where the first carbon black feedstock was introduced earlier.

Alternatively, the low-yielding carbon black feedstock may be introduced into the reactor and the reaction stream at a distance from the location where the first carbon black feedstock is introduced or injected into the reactor, and the distance may be at least 1 or at least 2 times the narrowest diameter (e.g., diameter 9 or 64) of the initial chamber 6 of the reactor (or at least 2 times the diameter of the reactor into which the first carbon black feedstock is introduced or injected). The distance may be at least 2.25, at least 2.5, at least 2.75, at least 3, at least 3.25, at least 3.5, at least 3.75, or at least 4 times the diameter of the initial chamber of the reactor (e.g., where the carrier gas and/or feedstock is electrically heated) (or at least 2.25, at least 2.5, at least 2.75, at least 3, at least 3.25, at least 3.5, at least 3.75, or at least 4 times the diameter of the reactor into which the first carbon black is introduced or injected).

The low-yielding carbon black feedstock may be introduced at positions 8 and/or 59 via one or more injectors.

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

The reaction stops in the quenching zone of the reactor (see 62 of Figure 6). As shown in Figure 6, quenching 62 is located downstream of the last raw material injection zone, and quenching fluid such as water is sprayed into the newly formed carbon black particle flow. Generally, quenching is used to cool the carbon black particles and reduce the temperature of the gas flow and reduce the reaction rate. Distance 67 is the distance from the beginning of the last raw material injection point to the quenching point 62, and will vary according to the position of the quenching. Optionally, quenching can be carried out in stages, or at several points in the reactor. Pressure spraying, gas atomization spraying or other quenching techniques can also be used. About completely quenching the reaction to form carbon black, any means of quenching the reaction downstream of the raw material for introducing the production of carbon black known to those skilled in the art can be used. For example, a quenching fluid (which can be water or other suitable fluids) can be injected to stop the chemical reaction.

After quenching, the cooled gas and carbon black are passed downstream to any conventional cooling and separation device, whereby the product is collected. The separation of the carbon black from the gas stream is easily accomplished by conventional devices such as a precipitator, cyclone separator, bag filter, or other devices known to those skilled in the art. After the carbon black is separated from the gas stream, the carbon black may optionally be subjected to a pelletizing step.

For any of the methods of the present invention, the carbon black produced is optionally not a carbon black having a core and a coating.

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

Alternatively, any one or more of the carbon black feedstock or other components used in the process of the present invention may be preheated prior to introduction into the reactor. Suitable preheating temperatures and/or preheating techniques may be used in the present invention, for example, as disclosed in U.S. Patent Nos. 3,095,273, issued to Austin on June 25, 1963; 3,288,696, issued to Orbach on November 29, 1966; 3,984,528, issued to Cheng et al. on October 5, 1976; 4,315,901, issued to Cheng et al. on February 16, 1982; 4,316,902, issued to Cheng et al. on February 16, 1988; 4,317,903, issued to Cheng et al. on February 16, 1988; 4,316,904, issued to Cheng et al. on February 16, 1988; 4,316,905, issued to Cheng et al. on February 16, 1988; 4,316,905, issued to Cheng et al. on February 16, 1988; 4,316,903 ... U.S. Patent No. 4,765,964, issued to Gravley et al. on August 23, 1990; U.S. Patent No. 5,997,837, issued to Lynum et al. on December 7, 1999; U.S. Patent No. 7,097,822, issued to Godal et al. on August 29, 2006; U.S. Patent No. 8,871,173B2 or CA682982, issued to Nester et al. on October 28, 2014, all of which are incorporated herein by reference in their entirety. Alternatively or in addition, the low-yielding carbon black feedstock can be preheated to a temperature higher than the typical temperature of the relatively high-yielding feedstock. For example, the low-yielding carbon black feedstock can be heated to a temperature in excess of 600° C., such as 600-800° C., even at ambient pressure. Because the low-yielding carbon black feedstock has a low concentration of asphaltenes, heating to such a high temperature does not produce a significant amount of coke or other solid non-carbon black materials. Alternatively or additionally, any one or more of the carbon black feedstocks may be combined with an extender fluid prior to introduction into the reactor, for example, as described in US Pat. No. 10,829,642 to Unrau, the entire contents of which are incorporated herein by reference.

Alternatively, the method is performed in the absence of at least one substance which is or contains at least one Group IA or Group IIA element (or ion thereof) of the Periodic Table.

Alternatively, in any method of the present invention, the method may include the step of introducing at least one substance that is or contains at least one Group IA or Group IIA element (or its ion) 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 a combination thereof. Any mixture of one or more of these components may be present in the substance. The substance may be a solid, a solution, a dispersion, a gas or any combination thereof. More than one substance with 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 locations. For the purposes of the present invention, the substance may be a metal (or metal ion) itself, a compound containing one or more of these elements, including salts containing one or more of these elements, etc. Preferably, the substance is capable of introducing a metal or metal ion into an ongoing reaction to form a 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 two carbon black generating raw materials; during the introduction of any one or two carbon black generating raw materials; after the introduction of any or all raw materials for generating carbon black; or after the introduction of all raw materials but before complete quenching. More than one substance introduction point can be used. The amount of the substance containing the IA group or IIA group metal can be any amount, as long as a carbon black product can be formed. For example, the amount of the substance can be such that there is an addition amount of 200ppm or more of the IA group or IIA group element in the carbon black product finally formed. Other amounts include about 200ppm to about 5000ppm or more, and other ranges can be about 300ppm to about 1000ppm, or about 500ppm to about 1000ppm of the IA group or IIA group element present in the carbon black product formed. These levels can be relative to the metal ion concentration. As described, these amounts of the IA group or IIA group elements present in the carbon black product formed can be relative to one element or more than one IA group or IIA group element, and therefore will be the combined amount of the IA group or IIA group elements present in the carbon black product formed. The substance may be added in any manner, including any conventional means. In other words, the substance may be added in the same manner as the feedstock to produce carbon black is introduced. The substance may be added as a gas, liquid, or solid, or any combination thereof. The substance may be added at one point or multiple points, and may be added as a single stream or multiple streams. The substance may be mixed with the feedstock, fuel, and/or oxidant prior to or during its introduction.

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

Carbon black can be characterized by: specific surface area, structure, aggregate size, shape and distribution; and/or chemical and physical properties of the surface. The properties of carbon black are determined by test analysis 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 following ASTM test procedure D6556. Iodine value can be measured using ASTM procedure D1510. Carbon black "structure" describes the size and complexity of carbon black aggregates formed by the fusion of primary carbon black particles with each other. As used herein, carbon black structure can be measured as the oil absorption value (OAN) of uncrushed carbon black according to the procedure described in ASTM D2414, which is expressed as milliliters of oil per 100 grams of carbon black. The compressed sample oil absorption value (COAN) measures the part of the carbon black structure that is not easily changed by applying mechanical stress. COAN is measured according to ATSM D3493. Aggregate size distribution (ASD) was measured according to ISO 15825 method using disc centrifuge photo sedimentation measurement with model BI-DCP manufactured by Brookhaven Instruments.

Carbon black materials having properties suitable for a particular application can 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 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 specifications.

The carbon black can have any STSA, for example, ⁵ to ²⁵⁰ m2/g, ¹¹ to ²⁵⁰ m2/g, ²⁰ to ²⁵⁰ m2/g, or higher, for example, at least 70 ^m2 /g, for example, ⁷⁰ to ²⁵⁰ m2/g, or 80 to ^{200 m2} /g, or 90 to 200 ^m2 /g, or ¹⁰⁰ to ^{180 m2} /g, ¹¹⁰ to 150 m2/g, ¹²⁰ to ^{150 m2} /g, etc. Alternatively, the carbon black can have an iodine number (I2No) of about 5 to about 35 mg _I2 per gram of carbon black (according to ASTM D1510).

The carbon black particles disclosed herein can have a Brunauer/Emmett/Teller (BET) surface area of 5 to ^{300 m2} /g, such as ⁵⁰ to ³⁰⁰ m2/g, such as 100 to ^{300 m2} /g, as measured by the BET technique according to the procedure of ASTM D6556. The BET surface area can be about 100 to about ^{200 m2} /g or about ²⁰⁰ to about ³⁰⁰ m2/g.

The Oil Absorption Number (OAN) may be from 40 mL/100 g to 200 mL/100 g, for example from 60 mL/100 g to 200 mL/100 g, for example from 80 mL/100 g to 200 mL/100 g, for example from 100 mL/100 g to 200 mL/100 g or from 120 mL/100 g to 200 mL/100 g, from 140 mL/100 g to 200 mL/100 g, from 160 to 200 mL/100 g, or for example from 40 mL/100 g to 150 mL/100 g or from 40 mL/100 g and 150 mL/100 g.

The COAN may be in the range of about 40 mL/100 g to about 150 mL/100 g, for example, between about 55 mL/100 g to about 150 mL/100 g, such as between about 80 mL/100 g to about 150 mL/100 g, or between about 80 mL/100 g to about 120 mL/100 g.

Carbon black can be a carbon product containing silicon-containing substances and/or metal-containing substances, etc., which can be achieved by including the introduction of such substances together with any one or both of the raw materials for producing carbon black or the introduction of such substances in addition to any one or both of the raw materials for producing carbon black. For the purposes of the present invention, carbon black can be a multiphase aggregate (also referred to as silicon-treated carbon black, such as ECOBLAK ^™ materials from Cabot Corporation) comprising at least one carbon phase and at least one metal-containing phase or silicon-containing phase.

As mentioned above, the carbon black may be rubber black, particularly reinforcing grade carbon black or semi-reinforcing grade carbon black.

Alternatively, the carbon black of the present invention may have a functional group or chemical group (e.g., derived from a small molecule or polymer, ionic or non-ionic) directly attached to the carbon surface (e.g., covalently attached). Examples of functional groups that can be directly attached (e.g., covalently attached) to the surface of carbon black particles and methods for surface modification are described in, for example, U.S. Pat. No. 5,554,739, issued to Belmont on September 10, 1996, and U.S. Pat. No. 5,922,118, issued to Johnson et al. on July 13, 1999, the entire contents of which are incorporated herein by reference. As an example, the surface-modified carbon black that can be used herein is obtained by treating carbon black with a diazonium salt, which is formed by the reaction of sulfanilic acid or p-aminobenzoic acid (PABA) with HCl and _NaNO2 . For example, surface modification by a sulfanilic acid or p-aminobenzoic acid process using a diazonium salt results in a carbon black having an effective amount of hydrophilic moieties on a carbon coating.

Carbon black may be surface modified according to U.S. Patent No. 8,975,316 to Belmont et al., the contents of which are incorporated herein by reference in their entirety.

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

Oxidized (modified) carbon black can be prepared in a manner similar to that for carbon black, as described in, for example, U.S. Pat. No. 7,922,805 issued to Kowalski et al. on April 12, 2011 and U.S. Pat. No. 6,471,763 issued to Karl on October 29, 2002, which are incorporated herein by reference in their entirety. Oxidized carbon black is carbon black that has been oxidized using an oxidant to introduce ions and/or ionizable groups onto the surface. Such particles can have a higher degree of oxygen-containing groups on the surface. Oxidants include, but are not limited to, oxygen, 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 oxidants (such as permanganates, osmium tetroxide, chromium oxide, or ammonium cerium nitrate). Mixtures of oxidants can also be used, particularly mixtures of gaseous oxidants such as oxygen and ozone. Other surface modification methods, such as chlorination and sulfonylation, can also be used to introduce ions or ionizable groups. The carbon black may be surface modified by any method known to those skilled in the art. For example, the carbon black may be heat treated as described in US 10767028, the entire contents of which are incorporated herein by reference.

Carbon black is used in a variety of applications, for example as a reinforcement material in rubber products such as tire components.

Carbon black can be incorporated into rubber products, such as for use in tire treads, especially in the tread of passenger car, light vehicle, truck and bus tires, off-the-road ("OTR") tires, aircraft tires, and the like; subtreads; wire skims; sidewalls; cushion gums for retreaded tires; and other tire applications.

Among other applications, the particles can be used in industrial rubber products such as engine mounts, hydraulic mounts, bridge bearings and isolators, tank tracks or treads, mining belts, hoses, gaskets, seals, blades, weather stripping products, bumpers, anti-vibration parts, etc.

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

Alternatively, the carbon black may be mixed into the rubber via a liquid masterbatch process. For example, a slurry containing the particles described herein may also be mixed with an elastomer latex in a barrel and then coagulated by adding a coagulant (solidifying) agent such as an acid using the technique described in U.S. Pat. No. 6,841,606.

Carbon black may be introduced according to 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 involve simultaneously supplying a particulate filler fluid and an elastomer latex fluid to a mixing zone of a coagulant reactor. The coagulant zone extends from the mixing zone, preferably with a gradually increasing cross-sectional area in a downstream direction from an inlet end to a discharge end. The elastomer latex may be natural or synthetic, and the particulate filler comprises, consists essentially of, or consists of the materials described above. The particulate filler is preferably supplied to the mixing zone as a continuous high-speed jet of an injection fluid, while 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 flow turbulence of the mixture in at least the upstream portion of the coagulant zone so as to substantially completely coagulate the elastomer latex and the particulate filler before the discharge end. Substantially complete coagulation may occur without the need for an acid or salt coagulant. As disclosed in U.S. Pat. No. 6,075,084, which is incorporated herein by reference in its entirety, additional elastomer may be added to the material emerging from the discharge end of the coagulum reactor. As disclosed in U.S. Pat. No. 6,929,783, which is incorporated herein by reference in its entirety, the coagulum may then be fed to a dewatering extruder. Other examples of suitable masterbatch processes are disclosed in U.S. Pat. No. 6,929,783 to Chung et al.; Application US2012/0264875A1 to Berriot et al.; Application US2003/0088006A1 to Yanagisawa et al.; and EP1834985B1 to Yamada et al.

Carbon black can be evaluated using natural or synthetic rubber in a suitable rubber formulation. The appropriate amount of carbon black to be used can be determined by routine experimentation, calculation, by considering factors such as the typical loading of standard ASTM black in comparable manufacturing processes, the specific parameters of the technology and/or equipment used, the presence or absence of other additives, the desired properties of the final product, etc.

The performance of carbon black as a reinforcing agent for rubber compounds can be evaluated by determining the performance of a rubber composition, for example utilizing particles, relative to a comparative rubber composition, which is similar in all respects except that a grade of carbon black suitable for a given application is used. In other methods, the values obtained for a composition prepared according to the present invention can be compared with values known in the art that are associated with desired parameters in a given application.

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

Cure curves were obtained by Rubber Process Analyzer (RPA 2000) according to ASTM D5289 at 0.5°, 100 cpm and 150C (NR) - 160C (SBR).

The performance characteristics of the cured samples can be determined by a series of appropriate tests. Tensile strength, elongation at break, and stress at various strains (e.g., 100% and 300%) are obtained via ASTM D412 Method A. Dynamic mechanical properties, including storage modulus, loss modulus, and tan δ, are obtained by strain sweep testing at 10 Hz, 60C, 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 ATSM D624.

According to the method of multiple reports, the undispersed area is calculated by analyzing the image of the cured rubber compound of the cut cross-sectional area obtained via a reflection mode optical microscope. Dispersion can also be represented by a Z value (after reticulation, according to S.Otto and Al at Kautschuk Gummi Kunststoffe, 58 Jahrgang, NR 7-8/2005, the method described in the article entitled "New Reference value for the description of Filler Dispersion with the Dispergrader 1000NT" is measured). Standard ISO 11345 sets forth a visual method for the quick and comparative evaluation of the macroscopic dispersion degree of carbon black and carbon black/silicon dioxide in rubber.

Abrasion resistance is quantified as an index based on the wear loss of the cured rubber by a Cabot Abrader (Lambourn type). Attractive abrasion resistance results can indicate favorable wear properties. Good hysteresis results can be associated with low rolling resistance (and correspondingly higher fuel economy) for motor vehicle tire applications, reduced heat build-up, tire durability, tread life and carcass life, fuel economy characteristics of motor vehicles, etc.

Iodine value (I2 value) is determined according to ASTM test procedure D1510. STSA (Statistical Thickness Surface Area) is determined based on ASTM test procedure D-5816 (measured by nitrogen adsorption). OAN is determined based on ASTM D2414. COAN is determined based on ASTM D3493 (e.g., D3493-20).

Unless otherwise indicated, all material proportions described herein as percentages are by weight.

The present invention will be further illustrated by the following examples, which are intended to be merely exemplary in nature.

The present invention includes the following aspects/embodiments/features in any order and/or in any combination:

1. A method for producing carbon black, comprising:

electrically heating a carrier gas to form a heated carrier gas such that pyrolysis of at least a portion of a carbon black feedstock occurs in a carbon black reactor by contact with the heated carrier gas, wherein the carbon black feedstock comprises at least one first carbon black feedstock and at least one low-yielding carbon black feedstock;

combining the at least one first carbon black feedstock with the heated carrier gas to form a reaction stream, wherein the at least one first carbon black feedstock comprises at least 10 weight percent of the total carbon black feedstock;

downstream combining at least one low-yielding carbon black feedstock into the existing reaction stream to form carbon black, wherein the at least one low-yielding carbon black feedstock comprises at least 10 weight percent of the total carbon black feedstock; and

Recovering the carbon black in the reaction stream, wherein the first carbon black feedstock is a liquid at the temperature and pressure in the chamber and has the following properties:

- Bureau of Mines Connection Index (BMCI) ≥ 100,

-H:C atomic ratio ≤ 1.23, and

-Specific gravity>1.02;

And wherein the low-yield carbon black feedstock has at least one of the following properties:

Bureau of Mines Connected Index (BMCI) < 100, or

H:C atomic ratio>1.23, or

Specific gravity ≤ 1.02, or

is a gas at room temperature and pressure, and

Wherein, based on the total carbon black raw materials, the at least one low-yield carbon black raw material is present in an amount of 10 wt %-90 wt %, and based on the total carbon black raw materials, the at least one first carbon black raw material is present in an amount of 10 wt %-90 wt %.

2. A method for producing carbon black comprising:

electrically heating a carrier gas to form a heated carrier gas such that pyrolysis of at least a portion of a carbon black feedstock occurs in a carbon black reactor by contact with the heated carrier gas, wherein the carbon black feedstock comprises at least one first carbon black feedstock and at least one low-yielding carbon black feedstock;

combining the at least one first carbon black feedstock and the at least one low-yielding carbon black feedstock as a blend or as separate additions at or approximately at the same location with the heated carrier gas to form a reaction stream, wherein the at least one first carbon black feedstock comprises at least 10 weight percent of the total carbon black feedstock and the at least one low-yielding carbon black feedstock comprises at least 10 weight percent of the total carbon black feedstock; and

Recovering the carbon black in the reaction stream, wherein the first carbon black feedstock is a liquid at the temperature and pressure in the chamber and has the following properties:

- Bureau of Mines Connection Index (BMCI) ≥ 100,

-H:C atomic ratio ≤ 1.23, and

-Specific gravity>1.02;

And wherein the low-yield carbon black feedstock has at least one of the following properties:

Bureau of Mines Connected Index (BMCI) < 100, or

H:C atomic ratio>1.23, or

Specific gravity ≤ 1.02, or

is a gas at room temperature and pressure, and

Wherein, based on the total carbon black raw materials, the at least one low-yield carbon black raw material is present in an amount of 10 wt %-90 wt %, and based on the total carbon black raw materials, the at least one first carbon black raw material is present in an amount of 10 wt %-90 wt %.

3. A method for producing carbon black, comprising:

electrically heating at least one first carbon black feedstock to form a reaction stream such that pyrolysis of at least a portion of the at least one first carbon black feedstock occurs in a carbon black reactor, wherein the at least one first carbon black feedstock comprises at least 10 weight percent of the total carbon black feedstock;

downstream combining at least one low-yielding carbon black feedstock into the existing reaction stream to form carbon black, wherein the at least one low-yielding carbon black feedstock comprises at least 10 weight percent of the total carbon black feedstock; and

Recovering the carbon black in the reaction stream, wherein the first carbon black feedstock is a liquid at the temperature and pressure in the chamber and has the following properties:

- Bureau of Mines Connection Index (BMCI) ≥ 100,

-H:C atomic ratio ≤ 1.23, and

-Specific gravity>1.02;

And wherein the low-yield carbon black feedstock has at least one of the following properties:

Bureau of Mines Connected Index (BMCI) < 100, or

H:C atomic ratio>1.23, or

Specific gravity ≤ 1.02, or

is a gas at room temperature and pressure, and

Wherein, based on the total carbon black raw materials, the at least one low-yield carbon black raw material is present in an amount of 10 wt %-90 wt %, and based on the total carbon black raw materials, the at least one first carbon black raw material is present in an amount of 10 wt %-90 wt %.

4. The method of any preceding or subsequent embodiment/feature/aspect, further comprising electrically heating the at least one low-yield carbon black feedstock.

5. The method of any preceding or subsequent embodiment/feature/aspect, wherein electrically heating the at least one low-yielding carbon black feedstock comprises heating the low-yielding carbon black feedstock to a temperature of 600-800°C.

6. The method of any preceding or subsequent embodiment/feature/aspect, further comprising electrically heating at least one of the at least one first carbon black feedstock and the at least one low-yielding carbon black feedstock.

7. The method of any preceding or subsequent embodiment/feature/aspect, wherein the electrical heating is achieved using an electric arc.

8. The method of any preceding or following embodiment/feature/aspect, wherein the electrical heating is achieved using a resistance or induction based heating element.

9. The method of any preceding or following embodiment/feature/aspect, wherein the heating element is magnesium oxide or yttria-stabilized zirconium oxide.

10. The method of any preceding or following embodiment/feature/aspect, wherein the temperature of the heated carrier gas is greater than 2000°C.

11. The method of any preceding or subsequent embodiment/feature/aspect, wherein the electrical heating is achieved using an induction or microwave based method that prevents direct contact between the electrode and the carrier gas or carbon black feedstock.

12. The method of any preceding or subsequent embodiment/feature/aspect, wherein the electrical heating is achieved using a plasma arc or a heating element in direct contact with the carbon black feedstock.

13. The method of any preceding or following embodiment/feature/aspect, wherein the low-yielding carbon black feedstock is at least one of:

a) The Bureau of Mines Connection Index (BMCI) is < 95, or

b) said gas at the temperature and pressure of the chamber, or

c) the H:C atomic ratio is >1.3, or

d) the specific gravity is ≤1.0.

14. The method according to any one of the preceding claims, wherein the low-yielding carbon black feedstock has the specific gravity of at most 1.02.

15. The method of any preceding or following embodiment/feature/aspect, wherein the low-yield carbon black feedstock comprises at least one of: vegetable or other plant-derived oils, biogenic ethanol, plant or animal-produced waxes or resins, oils made from animal fats, algae oils, oils made from pyrolysis of sewage sludge or agricultural waste, byproduct liquids from processing of biogenic materials, liquids produced by hydrothermal liquefaction of biogenic materials, crude tall oil, tall oil rosin, tall oil pitch, or tall oil fatty acids, oils produced from recycled materials, oils derived from pyrolysis of low-quality, off-spec or scrap tires, oils derived from pyrolysis of discarded or recycled plastic or rubber products, oils derived from pyrolysis of municipal solid waste, or oils derived from pyrolysis of biomass, or any combination thereof.

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

17. The method of any preceding or following embodiment/feature/aspect, wherein the first carbon black feedstock is a fraction obtained from distillation of tire pyrolysis oil.

18. The method of any preceding or following embodiment/feature/aspect, wherein the low-yielding carbon black feedstock is 50-90 weight % of the total feedstock input in the method.

19. The method of any preceding or following embodiment/feature/aspect, wherein the low-yielding carbon black feedstock is 60-90 wt % of the total feedstock input in the method.

20. The method of any preceding or subsequent embodiment/feature/aspect, wherein the carbon black reactor comprises: a first chamber in which the electrical heating occurs; and a throat downstream of the first chamber; and a reaction chamber downstream of the throat; and a quenching zone downstream of the reaction chamber, and wherein the first carbon black feedstock is injected into the throat and the low-yield carbon black feedstock is injected after the throat.

21. The method of any preceding or subsequent embodiment/feature/aspect, wherein the carbon black reaction comprises a second throat downstream of the reaction chamber and before the quenching zone, and the low-yielding carbon black feedstock is injected into the second throat.

22. The method of any preceding or following embodiment/feature/aspect, wherein the at least one first carbon black feedstock is introduced into the carbon black reactor at a first location and at least one separate location downstream of the first location.

23. The method of any preceding or following embodiment/feature/aspect, wherein the amount of the first carbon black feedstock introduced at the first location is greater than 50% of the total amount of the first carbon black feedstock.

24. The method of any preceding or subsequent embodiment/feature/aspect, wherein the at least one low-yielding carbon black feedstock is introduced into the carbon black reactor at at least two separate locations, wherein one of the separate locations is downstream of another.

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

26. The method of any preceding or subsequent embodiment/feature/aspect, wherein the at least one first carbon black feedstock is a blend comprising less than 5 wt% of a low-yield carbon black feedstock, based on the total weight of the first carbon black feedstock.

27. The method of any preceding or subsequent embodiment/feature/aspect, wherein the at least one low-yielding carbon black feedstock is a blend comprising less than 50 wt% of a high-yielding carbon black feedstock, based on the total weight of the low-yielding carbon black feedstock.

28. The method of any preceding or subsequent embodiment/feature/aspect, wherein the at least one low-yielding carbon black feedstock is a blend comprising less than 5 wt% of a high-yielding carbon black feedstock, based on the total weight of the low-yielding carbon black feedstock.

29. The method of any preceding or following embodiment/feature/aspect, wherein said low-yielding carbon black feedstock has said BMCI of <100.

30. The method of any preceding or subsequent embodiment/feature/aspect, wherein said low-yield carbon black feedstock has said H:C atomic ratio >1.23.

31. The method of any preceding or subsequent embodiment/feature/aspect, wherein the low-yielding carbon black feedstock is the gas at the temperature and pressure within the chamber.

32. The method of any preceding or subsequent embodiment/feature/aspect, wherein the recovered carbon black is N110, N121, N220, N231, N234, N299, N326, N330, N339, N347, N351, N358, N375, N539, N550, N650, N660, N683, N762, N765, N774, N787, or N990 grade carbon black.

33. Carbon black made by any method of any preceding or following embodiment/feature/aspect.

The present invention may include any combination of the above and/or following various features or embodiments as set forth in any sentence and/or paragraph herein. Any combination of features disclosed herein is considered to be part of the present invention, and there is no limitation on the features that can be combined.

The applicant specifically incorporates the full content of all cited references into the present disclosure. In addition, when the list of equivalent, concentration, or other values or parameters is given as a range, a preferred range or a preferred upper limit and a preferred lower limit, this should be understood as specifically disclosing all ranges formed by any upper range limit or preferred value and any range lower limit or preferred value, and whether the scope is disclosed separately. In the case of enumerating numerical ranges in this article, unless otherwise indicated, the scope is intended to include its endpoints and all integers and fractions within the scope. The scope of the present invention is not intended to be limited to the specific values cited when limiting the range.

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

Claims (32)

1. A method for producing carbon black, comprising: electrically heating a carrier gas to form a heated carrier gas such that pyrolysis of at least a portion of a carbon black feedstock occurs in a carbon black reactor by contact with the heated carrier gas, wherein the carbon black feedstock comprises at least one first carbon black feedstock and at least one low-yielding carbon black feedstock; combining the at least one first carbon black feedstock with the heated carrier gas to form a reaction stream, wherein the at least one first carbon black feedstock comprises at least 10 weight percent of the total carbon black feedstock; downstream combining at least one low-yielding carbon black feedstock into the existing reaction stream to form carbon black, wherein the at least one low-yielding carbon black feedstock comprises at least 10 weight percent of the total carbon black feedstock; and Recovering the carbon black in the reaction stream, wherein the first carbon black feedstock is a liquid at the temperature and pressure in the chamber and has the following properties: - Bureau of Mines Connection Index (BMCI) ≥ 100, -H:C atomic ratio ≤ 1.23, and -Specific gravity>1.02; And wherein the low-yield carbon black feedstock has at least one of the following properties: Bureau of Mines Connected Index (BMCI) < 100, or H:C atomic ratio>1.23, or Specific gravity ≤ 1.02, or is a gas at room temperature and pressure, and Wherein, based on the total carbon black raw materials, the at least one low-yield carbon black raw material is present in an amount of 10 wt %-90 wt %, and based on the total carbon black raw materials, the at least one first carbon black raw material is present in an amount of 10 wt %-90 wt %. 2. A method for producing carbon black comprising: electrically heating a carrier gas to form a heated carrier gas such that pyrolysis of at least a portion of a carbon black feedstock occurs in a carbon black reactor by contact with the heated carrier gas, wherein the carbon black feedstock comprises at least one first carbon black feedstock and at least one low-yielding carbon black feedstock; combining the at least one first carbon black feedstock and the at least one low-yielding carbon black feedstock as a blend or as separate additions at or approximately at the same location with the heated carrier gas to form a reaction stream, wherein the at least one first carbon black feedstock comprises at least 10 weight percent of the total carbon black feedstock and the at least one low-yielding carbon black feedstock comprises at least 10 weight percent of the total carbon black feedstock; and Recovering the carbon black in the reaction stream, wherein the first carbon black feedstock is a liquid at the temperature and pressure in the chamber and has the following properties: - Bureau of Mines Connection Index (BMCI) ≥ 100, -H:C atomic ratio ≤ 1.23, and -Specific gravity>1.02; And wherein the low-yield carbon black feedstock has at least one of the following properties: Bureau of Mines Connected Index (BMCI) < 100, or H:C atomic ratio>1.23, or Specific gravity ≤ 1.02, or is a gas at room temperature and pressure, and Wherein, based on the total carbon black raw materials, the at least one low-yield carbon black raw material is present in an amount of 10 wt %-90 wt %, and based on the total carbon black raw materials, the at least one first carbon black raw material is present in an amount of 10 wt %-90 wt %. 3. A method for producing carbon black, comprising: electrically heating at least one first carbon black feedstock to form a reaction stream such that pyrolysis of at least a portion of the at least one first carbon black feedstock occurs in a carbon black reactor, wherein the at least one first carbon black feedstock comprises at least 10 weight percent of the total carbon black feedstock; downstream combining at least one low-yielding carbon black feedstock into the existing reaction stream to form carbon black, wherein the at least one low-yielding carbon black feedstock comprises at least 10 weight percent of the total carbon black feedstock; and Recovering the carbon black in the reaction stream, wherein the first carbon black feedstock is a liquid at the temperature and pressure in the chamber and has the following properties: - Bureau of Mines Connection Index (BMCI) ≥ 100, -H:C atomic ratio ≤ 1.23, and -Specific gravity>1.02; And wherein the low-yield carbon black feedstock has at least one of the following properties: Bureau of Mines Connected Index (BMCI) < 100, or H:C atomic ratio>1.23, or Specific gravity ≤ 1.02, or is a gas at room temperature and pressure, and Wherein, based on the total carbon black raw materials, the at least one low-yield carbon black raw material is present in an amount of 10 wt %-90 wt %, and, based on the total carbon black raw materials, the at least one first carbon black raw material is present in an amount of 10 wt %-90 wt %. 4. The method according to any one of the preceding claims, further comprising electrically heating the at least one low-yielding carbon black feedstock. 5. The method of claim 4, wherein electrically heating the at least one low-carbon black yielding feedstock comprises heating the low-carbon black yielding feedstock to a temperature of 600 to 800°C. 6. The method of claim 1 or 2, further comprising electrically heating at least one of the at least one first carbon black feedstock and the at least one low-yielding carbon black feedstock. 7. The method of claim 1 or claim 2, wherein the electrical heating is achieved using an electric arc. 8. The method of claim 1 or claim 2, wherein the electrical heating is achieved using a resistance or induction based heating element. 9. The method of claim 8, wherein the heating element is magnesium oxide or yttria-stabilized zirconium oxide. 10. The method of any one of claims 1-9, wherein the heated carrier gas has a temperature greater than 2000°C. 11. The method of any one of claims 1-3, wherein the electrical heating is achieved using an induction or microwave based method that prevents direct contact between the electrodes and the carrier gas or carbon black feedstock. 12. The method of claim 3, wherein the electrical heating is achieved using a plasma arc or a heating element in direct contact with the carbon black feedstock. 13. The method according to any one of the preceding claims, wherein the low-yielding carbon black feedstock is at least one of: a) The Bureau of Mines Connection Index (BMCI) is < 95, or b) said gas at the temperature and pressure of the chamber, or c) the H:C atomic ratio is >1.3, or d) the specific gravity is ≤1.0. 14. The method according to any one of the preceding claims, wherein the low-yielding carbon black feedstock has the specific gravity of at most 1.02. 15. The method of any one of the preceding claims, wherein the low-yield carbon black feedstock comprises at least one of: vegetable or other plant-derived oils, biogenic ethanol, plant or animal-produced waxes or resins, oils made from animal fats, algae oils, oils made from pyrolysis of sewage sludge or agricultural waste, byproduct liquids from the processing of materials of biogenesis, liquids produced by hydrothermal liquefaction of biomaterials, crude tall oil, tall oil rosin, tall oil pitch, or tall oil fatty acids, oils produced from recycled materials, oils derived from pyrolysis of low-quality, off-spec, or end-of-life tires, oils derived from pyrolysis of discarded or recycled plastic or rubber products, oils derived from pyrolysis of municipal solid waste, or oils derived from pyrolysis of biomass, or any combination thereof. 16. The method of any one of the preceding claims, wherein the at least first carbon black feedstock comprises one or more of decant oil, slurry oil, coal tar, coal tar derivatives, ethylene cracker residue, or phenol cracker residue. 17. The method according to any one of the preceding claims, wherein the first carbon black feedstock is a fraction obtained from the distillation of tire pyrolysis oil. 18. The process according to any one of the preceding claims, wherein the low-yielding carbon black feedstock is 50-90 wt% of the total feedstock input to the process. 19. The process according to any one of the preceding claims, wherein the low-yielding carbon black feedstock is 60-90 wt% of the total feedstock input to the process. 20. A method according to any one of the preceding claims, wherein the carbon black reactor has: a first chamber in which the electrical heating occurs; and a throat downstream of the first chamber; and a reaction chamber downstream of the throat; and a quenching zone downstream of the reaction chamber, and wherein the first carbon black feedstock is injected into the throat and the low-yielding carbon black feedstock is injected after the throat. 21. The method of claim 20, wherein the carbon black reaction comprises a second throat downstream of the reaction chamber and before the quenching zone, and the low-yielding carbon black feedstock is injected into the second throat. 22. The method of any one of the preceding claims, wherein the at least one first carbon black feedstock is introduced into the carbon black reactor at a first location and at least one separate location downstream of the first location. 23. The method of claim 22, wherein the amount of the first carbon black feedstock introduced at the first location is greater than 50% of the total amount of the first carbon black feedstock. 24. The process according to any one of the preceding claims, wherein the at least one low-yielding carbon black feedstock is introduced into the carbon black reactor at at least two separate locations, wherein one of the separate locations is downstream of the other. 25. The method according to any one of the preceding claims, wherein the at least one first carbon black feedstock is a blend comprising less than 50 weight percent of a non-high-yielding carbon black feedstock, based on the total weight of the first carbon black feedstock. 26. The method according to any one of the preceding claims, wherein the at least one first carbon black feedstock is a blend comprising less than 5 weight percent of a low-yielding carbon black feedstock, based on the total weight of the first carbon black feedstock. 27. The method according to any one of the preceding claims, wherein the at least one low-yielding carbon black feedstock is a blend comprising less than 50 weight percent of a high-yielding carbon black feedstock, based on the total weight of the low-yielding carbon black feedstock. 28. The method according to any one of the preceding claims, wherein the at least one low-yielding carbon black feedstock is a blend comprising less than 5 weight percent of a high-yielding carbon black feedstock, based on the total weight of the low-yielding carbon black feedstock. 29. The method of any one of the preceding claims, wherein the low-yielding carbon black feedstock has the BMCI of <100. 30. The method of any one of the preceding claims, wherein the low-yielding carbon black feedstock has the H:C atomic ratio > 1.23. 31. The method of any one of the preceding claims, wherein the low-yielding carbon black feedstock is the gas at the temperature and pressure within the chamber. 32. The method of any one of the preceding claims, 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.