International Conference On Emanations in Modern Technology and Engineering (ICEMTE-2017) ISSN: 2321-8169

Volume: 5 Issue: 3 40 - 43
____________________________________________________________________________________________________________________

Investigation of Innovation in Carbon Black Manufacturing in the realm of Green

Environment

Sunil Satav, [Link] Yakkundi, Vipul Govindrao Badhe, Archana Gaikwad

Abstract—Carbon black is major input to tyres, paint, rubber, and plastic industries. Worldwide, Carbon black production is 14
million metric ton per annum. Major inputs for manufacturing process are fossil oil (Carbon black feed stock) and water. Thermal
process is used to crack oil in carbon particles in reactor at high temperature.

This paper focuses on innovative technologies used for carbon black manufacturing in the realm of reducing pollution and
[Link] focus of study is mainly on high potential contributor to environment pollution in these [Link] work also
focuses on the feasible advanced technologies which substitutes the conventional manufacturing process and recycling
opportunities in carbon black manufacturing process for clean environment.

Keywords— Air pollution, Carbon black process, Noise pollution, Power plant, Water pollution

__________________________________________________*****_________________________________________________

1] INTRODUCTION oxides, and the unburned portion of each of these pieces

present in the main process vent gas the oil feedstock storage
Carbon black is a highly dispersed product of thermal tanks are a source of organic emissions. Gaseous emissions
or thermo oxidative decomposition of hydrocarbons which are from the main process vent may be controlled with CO boilers,
the part of natural and industrial gases, as well as of oil and incinerators, or flares. The pellet dryer combustion furnace,
coal oils. Carbon black manufacture requires oils with a high which is, in essence, a thermal incinerator, may also be
content of aromatic hydrocarbons as a raw material for better employed in a control system. CO boilers, thermal
productivity. It is produced with the thermal decomposition incinerators, or combinations of these devices can achieve
method or the partial combustion method using hydrocarbons
essentially complete oxidation of organics and can oxidize
such as oil or natural gas as raw material.
sulfur compounds in the process flue gas. Combustion
Carbon black is used primarily in the tyre industry to efficiencies of 99.6 % for hydrogen sulfide and 99.8 % for CO
increase wear resistance, tear resistance, and strength of have been measured for a flare on a carbon black plant.
rubber. It is widely used in the production of high quality tread Particulate emissions may also be reduced by combustion of
rubber for all types of vehicles, and work pieces for the some of the carbon black particles, but emissions of sulfur
restoration of the tread, agricultural machinery, conveyor belts. dioxide and nitrogen oxides are thereby increased.
It is also used for the production of high-quality rubber Water emission form De-mineralized water plant, cooling
products, cable casings operated in the complicated conditions. tower, boiler blow down etc. Noise pollution is also major
It is also used in the manufacture of certain alloys, special issue due to various equipment, steam line etc.
kinds of paper, and electric products (e.g. electrodes) and the
galvanic elements. Carbon black is also used to produce the 2] PRESENT SCENARIO OF POLLUTION IN
copy paper, and ribbons for typewriters and printers. CARBON BLACK MANUFACTURING
Emissions from carbon black manufacturing include 2.1 Water pollution- Water requirement of Carbon black
particulate matter, carbon monoxide, sulfur compounds, manufacturing process is in various areas like Quenching
polycyclic organic matter, and wastewater discharge form process, Palletizing process and Power plants. These processes
power plant, cleaning system and traces elements. generate water effluent during processing like quench tower,
The source of emissions in the oil furnace process is the cooling tower blow down, De-mineralized water plant
main process vent. The vent stream consists of the reactor regeneration, floor washing, domestics uses etc.
effluent and the quench water vapor vented from the carbon
black recovery system. Gaseous emissions may vary Table 1: Summary of water effluent generated during Carbon
considerably according to the grade of carbon black being black process
produced. Organic and CO emissions tend to be higher for Area Parameter Quantity in
small particle production, corresponding with the lower yields Percentage
obtained. Sulfur compound emissions are a function of the Non process Oil, Grease, COD and 15%
feed sulfur content. The combined dryer vent emits carbon Area BOD
black from the dryer bag filter and contaminants from the use Cooling Conductivity and COD 60%
of the main process vent gas if the gas is used as a Tower Blow
supplementary fuel for the dryer. It also emits contaminants down
from the combustion of impurities in the natural gas fuel for DM Plant Conductivity, 24%
the dryer. These contaminants include sulfur oxides, nitrogen Effluent Hazardous Chemicals
40
IJRITCC | March 2017, Available @ [Link] (Conference Issue)
_______________________________________________________________________________________
International Conference On Emanations in Modern Technology and Engineering (ICEMTE-2017) ISSN: 2321-8169
Volume: 5 Issue: 3 40 - 43
____________________________________________________________________________________________________________________
Boiler Blow Temperature and 1% Volatile organic  Incomplete decomposition of
down Chemicals compounds (VOC) feedstock in the reactor.
(e.g. methane,
2.2- Emissions to air-The potential source of emission to air acetylene, ethylene)
is the „tail gas‟ which comes from the reactor after product Polycyclic aromatic  Incomplete decomposition of
separation. It contains hydrogen, carbon dioxides, reduced hydrocarbons (PAH) feedstock
sulphur compounds, sulphur oxides nitrogen compound and Particulate matters  Slip through filter system
volatile organic matter such as ethane and acetylene. (e.g. carbon black behind reactor
Table 2: Summary of emissions to air dust)  Slip through deducting filter
Specific Emission system behind dryer
Emission emission Concentration  Slip through thermal combustor
Parameters (kg/tone carbon (mg/Nm^3 at  Fugitive emission due to
black) 10%O2) storage, transportation and
Particulate matters 0.2-0.4 10-30 packing
Sulphur dioxides 6.5-22 400-1400 Heavy metals  Present as trace impurities in
(as SO2) some feed stock
Nitrogen Oxides 6.0-15 400-900
(as NO2) 2.3 Noise pollution- Carbon Black process uses reactor with
Carbon Monoxide 2.0-3.0 120-200 gas or oil as raw material to produce carbon black. It consists
Volatile organic Up to 0.7 Up to 50 of various equipment such as blowers, compressors, pumps
compounds and dryers Etc. Due to high revolution per minute and fluid
velocities high sound level is generated in various rotating
Table 3: Sources of emissions equipment in pumps and centrifugal fan, blowers. Power plant
Emission Origin and Utilities the noise level for steam turbine, gas turbine and
Carbon monoxide  Product of incomplete compressor ranged from 79 – 97.5 Db(A), 84.2 – 97 Db(A)
(CO) combustion in the reactor and 88.5 -100.5 Db(A) respectively .The average noise level
 Product of incomplete for steam turbine, gas turbine and compressor during the
combustion in dryers, boilers period under review was 91.8 Db(A), 93.31 Db(A) and
,flares Etc. 96.55Db(A) respectively.
Carbon dioxide (CO2)  Product of complete Table4: Summary of high sound level area / equipment in
combustion in the reactor carbon black process.
 Product of in complete Equipment Area Sound Level
combustion in dryers, boilers dB(A)
,flares etc. Packing blower Ware House 83.30
Oxides of  Oxidation of feed stock sulphur Process Air Blower Process 85.60
sulphur(Sox) compound in the reactor. Steam Turbine Turbine House 91.80
 Oxidation of sulphur compound Gas Turbine Turbine House 93.30
present in the tail gas. Compressor Utilities 96.50
Boiler Daearator Boiler House 98.10
vent
Reduced sulphur  Decomposition and partial Steam Line Traps Turbine 88.50
compound (Hydrogen oxidation of feedstock sulphur
sulfide (H2S), carbon compound in the reactor.
disulphide
3] INNOVATIVE METHODOLOGY ADOPTED TO
(CS2),carbonyl sulfide
REDUCE POLLUTION IN CARBON BLACK
(COS)
MANUFACTURING FOR CLEAN ENVIRONMENT
Oxides of Nitrogen  Oxidation of feed nitrogen The pollution and their major sources are discussed in
(NOx) compound in the reactor previous section. This section covers the recent methods being
 Thermal NOx form the reactor used in carbon black manufacturing.
 Fuel NOx form dryers, boilers, 3.1 Flue Gas Desulfurization or So2 Scrubbing Process
flares, etc.
 Thermal NOx form dryers, The main objective of adopting this process is to control
boilers, flares, etc. Sulphur dioxides (as SO2) [Link] flue gas
 Oxidative post treatment of desulfurization or So2 scrubbing process typically uses
carbon black with NO2and calcium or sodium based alkaline reagent. There are two types
HNO3 of sox scrubbing system i.e. wet and dry scrubbing system.
Hydrogen cyanide  Decomposition of feedstock The reagent is injected in the flue gas in a spray tower or
(HCN), Ammonia nitrogen compound in the directly in to the duct. The So2 absorbed, neutralized and /or
(NH3) reactor oxidized by alkaline reagent in to solid compound, either
41
IJRITCC | March 2017, Available @ [Link] (Conference Issue)
_______________________________________________________________________________________
International Conference On Emanations in Modern Technology and Engineering (ICEMTE-2017) ISSN: 2321-8169
Volume: 5 Issue: 3 40 - 43
____________________________________________________________________________________________________________________
sodium or sodium sulfate. The solid is removed from the waste The process of Deaeration is the mechanical removal of
gas stream using downstream equipment. dissolved gases from the boiler feed water. There are three
principles that must be met in the design of any deaerator. The
3.2 Separation of Lean Tail Gas and collection of fine feed water must be heated to the full saturation temperature
Carbon Black Particles corresponding to the steam pressure maintained inside the
deaerator. This will lower the solubility of dissolved gases to
Carbon black and gas mixture is passed through high zero. The heated water must be heated to the full saturation
efficiency Bag collectors for separation of Lean Tail Gas and temperature, corresponding to the steam pressure maintained
collection of fine carbon black particles. The filtered gas is inside the deaerator. Saturated feed water steam is vent out to
then sent to the onsite captive power plant for combustion and atmosphere to removed dissolved gases. Steam is at statured
generation of steam and electrical power through steam state, high velocity of steam form vent and generated high
turbines. A small part of Tail gas is also utilized to generate noise up to 98 Db (A).
heat for Carbon black drying process in the Tail gas fired
Rotary drum dryers. Boiler deaerator steam vent noise control is possible byrecycle
Tail Gas recycles a part of this waste tail gas and feed to of vent steam in process such as heater, VAM etc.
Carbon Black reactors as heat source for the Thermal cracking Deaerator steam is at low pressure at saturated temperature
reaction and replaces the auxiliary fuel oil being utilized. with dissolved gases like oxygen and CO. Steam will be
Through this process modification a substantial reduction of utilized in low heat process requirement to heat media such as
total plant oil requirement can be achieved and this reduction lithium bromide, oil etc.
is estimated in range of 12 to 15% on continuous basis. Table 6: Vent noise description
Prior to recycling, the Lean Tail Gas needs to be pre- Description Noise Pressure dB(A)
conditioned in order to achieve the desired heat input to the Vent to
reactors. The conditioning process of Tail gas involves 92.00 91.5 92.4 91.8 92.04
atmosphere
dehumidification and heating operation prior to injecting into Vent with
the reactor combustor. This system recycles tail gas in process 87.5 88.25 89.02 88.14 89.52
Silencer
and reduces emission of gases in atmosphere. Vent
connected
3.3 Noise controlling of equipments 74.20 72.05 73.78 72.98 74.57
to dumped
condenser
Carbon black manufacturing process contain equipments such
as Pump, Glob blower, Centrifugal blower, Steam turbine, Gas Steam traps are a type of automatic valve that filters out
turbine, Steam line steam traps, Deaerators, etc . Compressor condensate (i.e. condensed steam) and non-condensable gases
is high speed or reciprocating equipment. Compressor has such as air without letting steam [Link] disc
been identified as major noise source and this is steam traps have an intermittent, cyclical operating
[Link] is the most important noise source in characteristic. The valve mechanism comprised of a disc and
centrifugal compressors. This is really combination of two seat rings opens to discharge condensate for a few seconds;
effects one is the vortex shedding and another one is upstream and then closes for a generally longer period until a new
turbulence. The boundary layer over each blade is turbulent by discharge cycle begins.
the time it reaches the trailing edge. The turbulent layers on The opening and closing action of thermodynamic disc traps is
the top and bottom surface produce a fluctuation in the lift and caused by the difference in the forces acting on the bottom and
this fluctuation has a broad frequency spectrum. The top sides of the valve disc. These forces are essentially based
application of fluctuating force to the gas generates sound at on variations in kinetic and pressure energy of the typical
the same frequency. Therefore, broad noise is radiated. If the fluids involved; air, condensate, and steam. This high-
flow is turbulent when it enters a blade row, the turbulence is temperature, high-pressure steam discharges at high velocities
increased and the noise is greater. Turbulence noise is radiated produces a number of hazards to employees working near the
through the compressor casing, and it can be controlled by an traps. A-weighted noise levels alone can reach 100 dB (A).It
acoustic enclose after the compressor has been installed as it is generated noise 88.75 Db (A). It is higher to the WHO norms
almost impossible to eliminate the turbulence by design. though it is not continues operation but contributing noise in
plant area.
Table 5: Noise pressure description
Description Noise Pressure dB(A) Noise levels can be reduced significantly by fitting diffuser-
type silencers to each trap [Link] silencers operated
Noise
on the principle that by slowing the jet discharge velocity, the
Pressure
91 93 92.5 91.8 92.4 noise output would be reduced. This reduction was achieved
without
Enclosure by passing the discharge flow into a short pipe of enlarged
diameter through a flow-resistive material, typically stainless
Noise
78.9 steel wire wool.
Pressure with 78.4 79.1 78.98 78.6
0
Enclosure

42
IJRITCC | March 2017, Available @ [Link] (Conference Issue)
_______________________________________________________________________________________
International Conference On Emanations in Modern Technology and Engineering (ICEMTE-2017) ISSN: 2321-8169
Volume: 5 Issue: 3 40 - 43
____________________________________________________________________________________________________________________
Table 7: Effect of Diffuser on noise bed De-mineralized water plant has new technology as reverse
Description Noise Pressure in dB (A) osmosis with mix bed or with EDI Technology. Reverse
Noise osmosis with mix bed or with EDI plant the effluent quantity
Pressure 87. is reduced up to 15-20 %. Plant floor washing water is settle
87.5 85 87.5 90 87.5 down in the settling pond and willbe recycle in process for
without 5
Diffuser quenching purposed by putting activated carbon and sand
Noise filters .
Pressure Noise is the one of the major source of pollution in carbon
85 80 78 77.5 76 75 black manufacturing industries. It is reduced by using noise
Trap with
Diffuser damping technologies such as acoustic encloser for equipment,
silencer for vents. Acoustic encloser helped to reduce noise
3.4 Reduction of water effluent level up to 25 decibel (dB).Steam line trap noise level is
The major water effluent of carbon black manufacturing plant reduced up to 72.5 decibel (dB) by using diffuser to the out let
is the power plant where the effluent is generated form cooling of steam. Boiler pressurized deaerator vent noise is reduced
tower and De-mineralized plant. Cooling tower generate 60% form 98 decibel to 72 decibel (dB) by using close loop system.
of water effluent by blow down to maintain salt level in This also gives the heat and water recovery form vent steam.
cooling water. DM plant generates 24%of effluent form
regeneration of resin beds. Non process area and Boiler blow REFERENCES
down is small contribution of water effluent in process.
[1] I Drogin, "Carbon Black", Journal of the Air Pollution
Though it is small quantity it has been treated and recycled in Control Association,TI-2Chemical committee informative
process for zero water discharge. Cooling tower blow down report No.09. 16 March 2012
and De-mineralized water plant effluent are treated in reverse [2] Eric [Link], “Economic Impact analysis for the proposed
water osmosis membrane and recycled as cooling water carbon black manufacturing”,NESHAP,US
treatment. Cooling water blow down is avoided by selecting Environmental Protection Agency, May 2000
air condenser instead of surface condenser for steam turbine [3] Howard L. Conklin,“Water requirement of the carbon
black industries”, Geological survey, United state
exhaust steam condensate. Water requirement in air cooled Government printing office ,Washington, 1956
condenser is one time and there is no need to give the system [4] Report of ICBA “Carbon black users guide:safety health
blow down such as in cooling tower used for traditional water and environmental information”, International Carbon
cooled condenser to maintain water chemistry. Water black Association,2004
requirement for air cooled condenser is 95% less than the [5] Farhad Forouharmajd, Parvin Nassiri and Mohammad
Reza Monazzam, “Noise Pollution of air compressor and
cooling tower. its noise reduction procedure by using and enclosure,”
De-mineralized water treatment plant effluent are reduced by International Journal of Environmental Health
adopting new technologies such as Ultra filter – Reverse Engineering” “Vol. 1 Issue 1, Feb 2012
osmosis Mix Bed DM plant, Electrode ionization (EDI) [6] Dihel, G.M.,”Compressor Noise Control,” International
Process, Liquid-cell Membrane Contactor System. These Compressor Engineering Conference ,Paper 10,Purdue
University,1972
processes reduce chemical consumption of water treatment as [7] Brian P. Hemon , R Hilda Zonapalidou, Li Zhang, Keith J.
well as generate less water effluent. Sims and Linda R. Siwak, “Electrodeionization in power
plant application”, GE Power and water process
4] CONCLUSION technologies,1994
[8] Rayan Hamel, Ignao Sala, Nathan Fritz and Christropher
Frampton,“Pollution Presentation inters program”
The sole objective of adopting innovative methods in carbon Pollution Presentation Institute, Kansa State University”
black manufacturing is to control air emissions, pollution and Page No-2, 2006
reduce water effluent. The previous section indicates thatmain [9] Li-Shiang Liange , Lu Wang , U.S. Filter, Lo well and
source of air pollution is from boiler and dryer stack, where Massachusetts, “Continuous electrodeionised process for
Sox level is high even though it is not deviating Indian production of ultra pure water”, Pure water and chemical
conference,2001
environment standards norms. It contributes to increase air [10] J.O. Osarenmwinda and A. A. Onojoserio,“Noise
pollution. It can be reduce to the level of 5 to 25 ppm form 350 pollution in a refining and petrochemical company in
ppm by placing flue gas desulphurization unit. Nigeria”,International Journal of Engineering Research
Desulphurization unit byproduct has acceptance for land and Applications,Vol. 5, Issue 4, April 2015 , Page.01-05
filling and fertilizer. There are few other sources for air [11] Randall F. Braoon ,Industrial Noise control and Acoustic,
Louisiana Tech University , Chapter 5,2001
pollution in plant like vents and leakages. These can be
[12] Parag Mishra and Dr. Manoj Arrora”, “A Review of
controlled by good engineering practices and preventive literature on air cooled steam condenser”, International
maintenance. This also reduces the suspended particulate in Journal of Research in Aeronautical and Mechanical
the atmosphere. Suspended particulate level changes by Engineering, Volume 1, Issue 10, October 2015
location, vehicle movements also, which is taken care by
proper housekeeping and vehicle traffic management.

De-mineralized water plant effluent is treated in reverse

osmosis and multi effect evaporator and water is recycled in
plant. This gives zero water discharge (ZLD). Ion exchange
43
IJRITCC | March 2017, Available @ [Link] (Conference Issue)
_______________________________________________________________________________________