Lucrative Business Opportunities in Manufacturing of Carbon Black.
Carbon black (also known as acetylene black, channel black, furnace black, lamp black, and thermal black) is a result of incomplete combustion of heavy petroleum products like FCC tar, coal tar, and ethylene cracking tar. Carbon black is a Para crystalline carbon with a high surface-area-to-volume ratio, albeit one that is lower than activated carbon. It differs from soot in that it has a much higher surface-area-to-volume ratio and a considerably lower polycyclic aromatic hydrocarbon (PAH) content (negligible and non-bioavailable). Carbon black, on the other hand, is commonly used as a model compound for diesel soot in diesel oxidation experiments. Carbon black is primarily used in tires and other rubber items as a reinforcing filler. Plastics, oils, and ink are all examples of this.
Uses of Carbon Black:
Carbon black is most commonly used as a dye and strengthening process in vehicle tires. Carbon black also helps to conduct heat away from the tire’s tread and belt area, reducing thermal damage and extending tire life. Belts, hoses, and other non-tire rubber products account for around 20% of global demand.
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The remaining pigment is mostly used in inks, coatings, and plastics. Carbon black is applied to polypropylene to absorb ultraviolet radiation, which would otherwise weaken the material. Some radar absorbent papers, photocopier and laser printer toner, and other inks and paints contain carbon black particles. As a food coloring, carbon black derived from plants is used. Carbon black, a color pigment, has been commonly used in food and beverage packaging for many years. In the United States, parts of Europe and Asia, and South Africa, it’s used in multi-layer UHT milk bottles, as well as microwavable meal trays and meat trays in New Zealand.
Manufacturing process:
Carbon black is made using hydrocarbons such as oil or natural gas as a raw material and the thermal decomposition or partial combustion methods. Carbon black has different properties depending on the production process, so it’s divided into different categories. Carbon black produced by the furnace process, which is now the most widely used form, is referred to as “furnace black,” as opposed to carbon black produced by other methods.
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The Black Furnace Process: This process produces carbon black by partially combusting petroleum or coal oil as a raw material (feedstock oil) in high-temperature gases. Due to its high yield, this method is ideal for mass production and allows for extensive control over properties such as particle size and shape. This is the most popular process for producing carbon black at the moment.
The Channeling Process: This process produces carbon black by contacting partially combusted fuel, which is made from natural gas as a raw material, with channel steel (H-shaped steel) and collecting the carbon black that results. This system has yield and environmental problems, and as a result, the furnace process has taken over as the primary mass production method. However, this process produces carbon black with a large number of functional groups on the surface, which can be used in some painting applications.
Acetylene Black Process: The Acetylene Black Process is a method of producing black acetylene By thermally decomposing acetylene gas, carbon black is obtained. It is primarily used for electric conductive agents and provides carbon black with higher structures and crystallinity.
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The Lampblack Method: This method collects soot from fumes produced by burning oils or pine wood to produce carbon black. This process, which has been around since before Christ, is not appropriate for mass production. However, since it provides carbon black with a specific hue, it is used as a raw material for ink sticks.
Market outlook:
In 2020, the carbon black market was worth USD 15,495.32 million, and it is expected to develop at a CAGR of about 5.15 percent over the forecast period (2021-2026). The market was dominated by the tyres and industrial rubber products application segment, which is expected to expand over the forecast period. Because of its influence on the mechanical and dynamic properties of tyres, carbon black is one of the most commonly used reinforces in the tyre industry.
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Incomplete combustion of heavy petroleum products such as coal tar, FCC tar, or ethylene cracking tar produces carbon black. Process form, application, and geography are all used to segment the carbon black market. The market is divided into four types of processes: furnace black, gas black, lamp black, and thermal black. Tires and automotive rubber goods, plastics, toners and printing inks, paints and coatings, textile fabrics, and other applications make up the industry. The tyres and automotive rubber products application is the largest segment of the carbon black market, accounting for roughly 75% of total market share. Tires made of carbon black are used in automobiles. It’s used as a filler as well as a reinforcing agent for power.
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It’s used in a variety of tyre formulations with various rubber forms to customise tyre performance properties. The global tyre production volume reached 16.8 million metric tonnes in 2019, according to IRSG (International Rubber Study Group). Furthermore, from 2.36 billion units in 2019, the total global tyre market volume is forecast to hit 2.75 billion units by 2024. In light of COVID-19’s effects, the global tyre industry is expected to recover slowly in 2021, with a substantial recovery beginning in 2022.
Q1: What are the key considerations when setting up a manufacturing plant for Carbon Black?
Answer: When establishing a Carbon Black manufacturing plant, it is essential to consider the plant location’s proximity to raw material sources and end-user markets, availability of utilities like water and power, environmental compliance and regulations, plant layout for optimum workflow and safety, and the technological sophistication of manufacturing equipment to ensure production efficiency and product quality.
Q2: What are the environmental considerations for setting up a Carbon Black manufacturing plant?
Answer: The production of Carbon Black generates emissions and waste products which need to be managed effectively to mitigate environmental impact. It is crucial to incorporate advanced emission control technologies, proper waste disposal mechanisms, and implement sustainable practices such as energy and resource optimization. Securing necessary environmental permits and compliance with local, state, and federal environmental regulations is also imperative to operate the plant responsibly and sustainably.
Q3: How important is the role of technology and automation in Carbon Black manufacturing?
Answer: Technology and automation play a pivotal role in Carbon Black manufacturing. Advanced technologies enable precise control over the production process, ensuring consistent product quality, and optimized resource utilization. Automation aids in minimizing manual intervention, reducing human error, and enhancing production efficiency and safety. Investment in research and development for technological advancement is also crucial for developing new products and staying competitive in the market.
Q4: What are the financial implications of setting up a Carbon Black manufacturing plant?
Answer: Setting up a Carbon Black manufacturing plant involves significant financial investment in land, building, machinery, technology, and raw materials. The operational costs, including labor, utilities, maintenance, and raw materials, need to be factored in while planning the budget. Additionally, compliance with environmental regulations may incur extra costs for emission control and waste management. A comprehensive financial plan, considering capital expenditure, operational expenditure, and potential return on investment, should be developed to assess the project’s viability.
Key Players:
- Cabot Corp.
- Birla Carbon
- Tokai Carbon Co. Ltd.
- Continental Carbon Company
- Omsk Carbon Group
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