Lamp black process

However, besides the general principle, today s lamp black production units have very little in common with the ancient carbon black ovens. Smoking chimneys and settlement chambers have been replaced by highly sophisticated filtering systems. 

The lamp black apparatus consists of a cast-iron pan that holds the liquid feedstock, which is surmounted by a fireproof flue hood lined with refractory bricks. The air gap between the pan and the hood, as well as the vacuum present in the system, help to regulate the air supply and thus enable the manufacturer to fine-tune the carbon black s ultimate properties. Though radiant heat from the hood causes the raw material to vaporize and partially combust. Most of it is converted into carbon black. 

In order to separate the soUds, process gases containing carbon black are passed through a filter after the cooling stage. Onward processing is similar to that of the furnace black manufacture. 

These carbon blacks are characterized by a broad primary particle size distribution, ranging from approximately 60 to over 200 nm and are widely used in a number of 

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The lamp black process is the oldest industrial-scale production process [4.8], [4.17],... 

The lamp black process is only partially continuous. The feedstock, oil with a high aromatic hydrocarbon content, is burned in flat steel vessels up to 1.5 m in diameter (Fig. 56). The oil is continuously introduced into the vessel to keep a constant feedstock level. The off-gas containing carbon black is sucked into a conical exhaust pipe, which is coated with a ceramic inner liner and leads to the collecting system. The properties of the carbon black can be influenced to some extent by variation of the distance between the vessel and the exhaust and the amount of air sucked into the apparatus. One lamp black apparatus can produce 100 kg/h. The production process must be interrupted at certain time intervals to remove coke-containing residues from the vessels. 

Thermal-oxidative decomposition Furnace black process Degussa gas black process Lamp black process Aromatic oils on coal tar basis or mineral oil, natural gas Coal tar distillates Aromatic oils on coal tar basis or mineral oil... 

The lamp black process (Figure 4.7) is the oldest commercially used carbon black production process [4.8, 4.15]. 

The lamp black process is simply an industrialized version of the old lamp black production techniques. Oil in flat cast iron pans up to 2 m in diameter is burnt under an extraction hood with a nonstoichiometric quantity of air. The carbon... 

Feedstock for the lamp black process aromatic compound-rich oils... 

The lamp black process produces particularly coarse particulate carbon black with a high density ( heavy black ). Due to the broad particle size distribution of 60 to 200 nm, it has not been possible to replace lamp black with furnace black in some applications. 

The reaction products are quenched by water sprays in a cooling zone and the carbon black separated in filter units. The yield is ca. 35% of the carbon content of the feedstock and combusted gas. The residual gas consists almost entirely of hydrogen and can be mixed with natural gas for heating the furnace or for diluting the gas to be pyrolyzed. Coarser carbon black is produced than in the lamp black process, with primary particle sizes of 120 to 200 nm or 300 to 500 nm being attained depending upon whether the natural gas is diluted with inert gas or not. 

Production has continued in one form or another into recent times. Toch (1916), for example, states that Lampblack is the condensed smoke of a carbonaceous flame, and at present is made from a hydrocarbon oil of the type of dead oil, or it may be made from a number of distillates which on burning give a condensed black soot. Lampblack is stiU made from resinous woods, tar and pitch where the dead oil is not obtainable. The lamp black process is StiU used to a limited extent Buxbaum (1998) describes ftie use of oil with a high aromatic hydrocarbon content being burnt in large flat steel vessels, ftie off-gas containing ftie carbon black being sucked up into a conical exhaust pipe. 

The lamp black process is likely the oldest industrial process and has consequently been the object of numerous engineering variants. Figure 4.2 describes the principle of a typical modem plant. The partial combustion of a feedstock (oil generally) in an atmosphere purposely poor in oxygen produces smoke, which is cooled down and filtered to recover carbon black particles that are subsequently flocculated. The control of the pyrolytic process is loose and results in a large distribution of elementary particle sizes (from 60 to 200 nm). This fabrication process tends to be abandoned today in favor of the much cleaner and more versatile furnace one. 

Niobium pentoxide can be reduced with carbon in a two-step process, called the Balke process. Formation of the carbide is the first step. The oxide is mixed with the stoichiometric amount of lamp black, placed in a carbon cmcible, and heated in vacuum to 1800°C ... 

The production process or the feedstock is sometimes reflected ia the name of the product such as lamp black, acetylene black, bone black, furnace black, or thermal black. The reason for the variety of processes used to produce carbon blacks is that there exists a unique link between the manufactuting process and the performance features of carbon black. 

The increasing demand led to new production processes. The most important process today is the furnace black process. It was developed in the United States in the 1930s and substantially improved after World War II. It is a continuous process, which allows the production of a variety of carbon black types under carefully controlled conditions. Nearly all rubber grades and a significant part of pigment-grade carbon blacks are now manufactured by the furnace black process. Nevertheless, other production processes, such as gas black, lamp black, thermal black, and acetylene black processes, are still used for the production of specialties. 

Carbon black is produced by the partial combustion or thermal decomposition of hydrocarbons. Several methods are used, including the furnace black, thermal black, lamp black and acetylene black processes. The furnace black process is the most common. In this process, natural gas (or another fuel) is burned to form a hot gas stream that is directed into a timnel. An aromatic oil is sprayed in and the black forms as the gas moves down the tunnel. The reaction is quenched with the addition of water, and the product is collected as a low density powder (fluffy black) or is further processed into millimeter sized peUets. 

Carbides generally manufactured by reacting metals or metal oxides with carbon (lamp black) at high temperatures (1200 to 2300°C). The processes utilized are ... 

Several methods can be used for the production of carbon black. The Lampblack Process, the oldest of all, was developed by the Chinese. Initially, vegetable oil was burned in small lamps with tile covers to accumulate the carbon black formed. Later, shallow pans were used in systems with a restricted air supply. Carbon black in this process was recovered from smoke in settling chambers. This method is still used for production of small quantities of carbon black. The Channel Black Process is another method useful in the past and not important for present production. Natural gas is used as a raw material in this process it is burned in close proximity to steel channels on which carbon black is deposited. Carbon black is removed from the channels by scrapers and falls into hoppers beneath the channels. This process was discontinued in the USA in 1976 because of the price of natural gas, smoke pollution, and low yield. It is still being used in Germany, Eastern Europe, and Japan. 

When hydrocarbons are not completely incinerated, carbon black is obtained. Under suitable conditions this may contain not only particles of classical soot, but also fullerenes. The trace existence of fullerenes in lamp black was first proven by mass spectrometry, but after working out appropriate protocols for the reaction, smoking flames can by now be used for the production of weighable amounts. Benzene is the most common source of carbon for this process. It is mixed with oxygen and argon and burned in a laminar flame (Figure 2.18). The resulting mixture contains soot, polycychc aromatic compounds and a certain fraction of fullerenes that make up 0.003-9.0% of the soot s total mass. Other hydrocarbons like, for example, toluene or methane may be employed as well. 

The first activated carbon produced in America was developed accidently from an endeavor to find utility for leached black-ash, a waste product in the manufacture of soda pulp.26 When pulverized, black-ash resembles lamp black, and a factory was erected to process it into a pigment. Because of certain cblor characteristics, however, the finished pigment was not generally accepted by the paint and ink industries. Vigorous efforts to find other sales outlets were of no avail and the factory was about to be abandoned, when, quite by accident, one of the workers stumbled on the discovery that black-ash has decolorizing power. The product, now named Filtchar, was sold as a substitute for bone char and fuller s earth. Marketing difficulties soon developed because of uneven quality of the product some batches were satisfactory, others were not. Very few tests were then available to measure decolorizing power and none were suitable for quality control of the Filtchar. 

Carbon blacks are manufactured by three production processes, furnace black, lamp black and gas black. Each process gives a range of surfaces with gas blacks having acidic groups while furnace blacks are weakly basic. 

Synonyms /Acetylene black Carbon black acetylene Channel black Charcoal Cl 77266 Furnace black Lamp black Qil-fumace black Pigment black 6 Pigment black 7 Thermal acetylene black Thermal atomic black Thermal black Vegetable carbon D nilion Finely divided particles of elemental carbon obtained by incomplete combustion of hydrocarbons (channel or impingement process)... 

Carbons black includes several types of carbons, such as acetylene black, channel black, furnace black, lamp black. Commonly, their names are referred to the process or the source material from which they are made. Among those, the production of furnace black is the most important. Its production process consists in feeding a furnace with natural gas and aromatics oils as feedstock, where is vaporized and then pyrolyzed. Vulcan XC-72 (a furnace black from Cabot Corporation) is the most widely used catalyst support for low-temperature fuel cells due to their low cost and high availability, being this material used as standard to compare other types of carbons. Vulcan XC-72, formed by nanoparticles of 20-40 nm, has an electrical conductivity of 4 S cm a sulphur content of 0.05 %, and a negligible oxygen content [13]. Within the textural properties Vulcan carbon has a superficial area of 252 m g with a total pore volume of 0.63 cm g and a pore size distribution around 15 nm [14]. 

Usually after the carbon black synthesis a cooling step is apphed to stop the growth of the particles. Various types of oils are used as raw materials in the different industrial processes. Some processes apply natural gas as fuel to produce the required energy for the cracking reaction. The carbon black types, which are produced based on the particle combustion technology, are lamp black, furnace black, the Super /ENS ACO products, and the carbon black produced as by-products of the shell gasification process. ... 

Carbon black was produced even in pre-industrial times, from oils and resins, for the manufacture of pigments. At the beginning of the 19 th century, the lamp black and thermal black processes were introduced, which used mainly aliphatic hydrocarbons (natural gas) as raw material. 

Carbon black (CB) is indisputably the most widely used reinforcing filler in NR formulations. It improves tensile and tear strengths, modulus and hardness, abrasion and thermo-oxidative resistance, etc. of NR-based materials. CB is manufactured by a variety of processes, including the channel process, to produce furnace black, thermal black, lamp black and acetylene black. NR-based composites and nanocomposites with the addition of CB exhibit the monotonous black colour to the finished goods. 

Carbon blacks are, in effect, soots prodnced by incomplete combustion of volatile organic materials, principally oil and gas. As snch they have been made and used as pigments for well over a thousand years. Their prodnction as fillers for polymers has only been carried out since the early part of this centnry. Dnring this time, there have been four main processes resulting in prodncts of different characteristics furnace, channel, thermal and lamp blacks. 

Take five pai-ts by weight of lamp black, eleven of sulphur, and twenty-five of meal powder, and thoroughly mix. Then add a weak solution of gum water, sufficient only to make the mixture into the consistency of a stiff paste. Roll or flatten this out and cut it up into cubes of one quarter-inch sides. Place these on a disli, in a warm place, and allow them to dry gradually. The more gradually they are dried the better, and a week is not too long to allow for the process. Svhen perfectly dry, fix the cubes separately on straw-like fibres similar to tliose used in carpet brooms. The Japan e themselves... 

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