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Term Paper II
Carbon Black Production Plant
Changwichan
Pianjing
Thammasatta
Ratchapongsirikul
Khorungkul
Cheawtada
Nawapan
Aroonvilairat
104009
104097
104098
104100
104101
104102
104103
104104
Content
Page
List of Tables
List of Figures
ii
iii
1. Introduction
2. Carbon black production statistics
3. Importance of carbon black industry
4. The carbon black process
5. Major environmental issues
6. Point sources of pollution and their characteristics
7. Industrial waste abatement
8. Possible cleaner production aspects
8.1 Waste segregation
8.2 The process modification of cleaner production
9. Case study of Thai carbon black industry in Thailand
9.1 Waste sampling and monitoring
9.2 Material balance
10. Conclusion
References
1
1
2
3
6
6
8
10
11
12
13
13
14
15
16
ii
List of Tables
Table
1
2
3
4
5
6
7
Page
Point sources of pollution and its characteristics from
carbon black process
The characteristics of air pollution from carbon black
process
The characteristics of wastewater from carbon black
process
The segregation of wastes in carbon black process
The parameters for air sample
The parameters for water sample
The monitoring program and frequency
7
7
8
12
14
14
14
iii
List of Figures
Figures
1
2
3
4
5
6
7
8
9
10
Page
World carbon black demand
Portions of carbon black production in some countries
The worldwide usage of carbon black
The carbon black manufacturing processes
Heat recovery system from carbon black process
NOx, Sox and particulate matter management
The management of fugitive particulate matter
Schematic diagram of wastewater treatment from carbon
black process
Schematic diagram of waste from carbon black process
Simple material balance
2
2
3
5
8
8
9
10
11
14
North America
21%
Other Regions
16%
Asia / Pacific
45%
18%
US
China
Italy
Spain
1%
2%
2%
3%
CIS*
France
India
Sweden
1% 0%
Japan
Brazil
UK
Portugal
Germany
South Korea
Netherlands
Other countries
15%
20%
3%
3%
3%
4%
15%
4%
5%
19%
3
Furthermore, carbon black also designed to transform electrical characteristics from
insulating to conductive in products such as electronics packaging, safety applications,
and automotive parts.
9%
1%
Rubber application
P igment
Ingredient in deverse
application
90%
4
Oil Furnace process
This process has two basic concepts. First, carbon feed stock is converted from fluid to
gas (smoke) by heat and incomplete combustion process. Second, gas (smoke) from
incomplete combustion will be converted to solid (carbon black) by filtering process and
drying process. This technology uses water as a key role for stop reaction and extraction
carbon black. The details of process are described below;
Step 1: Feedstock oil is pumped from the storage tank into the reaction furnace through
oil pre-heaters. At the same time, combustion air is also preheated and supplied to the
reaction furnace. By preheating both feedstock oil and air to a high sensible heat energy, a
high yield of product is obtained.
Step 2: Feedstock oil then is burned in the reaction furnace. The temperature of
combustion is limited at 1320 to 1540C by using water to cool down to inhibit the
complete combustion in the reaction furnace. Then the incomplete combustion oil is
became carbon black fine particle or smoke.
Step 3: Inject the quenching water at the quench zone in the reaction furnace to cool
down the temperature to 500C to stop the incomplete combustion reaction. Carbon black
and by product, tail gas, are formed in this step at the quench zone. The exhaust gases
entraining the carbon particles are further cooled to about 230C by passage through heat
exchangers and direct water sprays.
Step 4: The mixture, carbon black and off gas, then are separated by sending to bag
filters. A cyclone is used for the primary collection system. Then the filtered carbon black
particle is sent to further process, the wet pelletizers.
Step 5: The filtered carbon black then transferred to wet pelletizers to increase bulk
density. Amount of water, molasses and carbon black are mixed with an appropriate ratio.
Then the wet pellets are dried in rotary dryers, which are heated by combusting tail gas.
Step 6: Finally the dried pellets then are conveyed into the product storage tank or in
storage bag.
The major waste from this process will be generated as off gas which comes from bag
filter house. Off gas contains several products of carbon feed stock combustion such as
carbon monoxide (CO), sulfur dioxide (SO2), nitrogen oxide (NOx), hydrogen (H2),
nitrogen (N2), particulate matter, steam and heat. The proportion of ingredients of off gas
depend on the type of carbon feed stock. However, due to off gas contain high level of
heat, it is recycled for steam making process. Optional steam will be used for power
generation or sell for another industry. Steam making process has to use water which is
treated to remove mineral (demineralization process). Because of untreated water may
interrupt boiling process and may cause explosion from boiler.
The flowchart of carbon black manufacturing processes is shown in Figure 4.
Raw water
Burner oil
Combustion air
Atomizing steam
Treated water
Oil cracking
Steam making
Off gas
pelletization
Water
Molasses
Off gas
Combustion air
Drying
Moisture
Flue gas
Packaging
6
Water pollution
- In case of emergency, the scrubber will be taken in the process and the wastewater
will contain particulate matter and acid water.
- High temperature water from cooling tower and equipment cooler unit
- Blow down water from back wash boiler
- Back wash water which contain high concentration of minerals
- Ground washing wastewater
- Domestic wastewater
Solid waste
Solid waste from carbon black process may be classified into 2 categories, which are
general and hazardous waste
- General waste from office and canteen
- Solid waste from process and packaging such as pallet, paper, plastics and
polypropylene bags
- Hazardous waste (carbon black) from wastewater treatment plant
Noise pollution
Noise pollution from carbon black processing may originate from Pneumatic conveyor
blower, Mixer and Dryer.
Sources
- Oil storage tank
- CO Heater
- Scrubber
Carbon black separating process
1. Filtering
- Bag filter
- Pneumatic blower
2. Mixing
3. Drying
- Mixer
- Dryer feeder
- Rotary dryer
Pollutant characteristics
- Oil storage tank vent gas
- Thermal problem
- Particulate matter,
combustion gases
- Wastewater
- Vent gases
- Smoke
- Noise pollution
- Particulate matter
- Noise pollution
- Noise pollution
- Particulate matter
- Noise pollution
- Flue gas
Phase/operation
Sources
Water treatment and steaming process
1. Demineralization
- Back wash
2. Steaming
- Boiler
- Packing
2. Storage unit
- Warehouse
Pollutant characteristics
- Mineral wastewater
- Blow down water (high
temperature)
- SOx and NOx
- Particulate matter
- Solid waste
- Solid waste
Carbon
black
process
Off Gases
Steam
Sell to Thai
Rayon
Company
Boiler
Steam
Power
generator
Condenser
Cooling
tower
Process
Off gas
Boiler
Dry scrubber
Stack
Reactor
smoke
Bag Filter
Pneumatic
Blower
Dryer feeder
Central
Vacuum
system
Packaging
Dust
Storage
Disposal
Figure 7 The management of fugitive particulate matter
Water pollution
Water pollution from carbon black process can be divided into 2 categories: process and
domestic wastewater, then they will be separately treated.
The process wastewater from wet scrubber, spill cleaning up mainly containing carbon
black and oil will be collected and treated by physico-chemical process in the wastewater
treatment plant. The treated effluent will be directly discharge from the polishing pond
into the Chaophraya River. Sediment from three settling ponds will be removed and
disposed at secured landfill.
The domestic wastewater from canteen, office will be pre-treated at site by oil and grease
trap or septic tank, and go through aerobic biological treatment and the overflowed water
from polishing pond are discharged into the river as shown in Figure 8.
10
Flocculation and
coagulation tank
Domestic
wastewater
Settling pond
I
Pretreatment
Settling Pond
II
Settling pond
III
Aerobic biological
treatment
Polishing pond
Reuse/recycle
Discharge to river
Figure 8 Schematic diagram of wastewater treatment from carbon black process
11
For carbon black industry, cleaner production will be focused on eliminate or segregate
wastes and reduce the quantity and toxicity of emission.
8.1 Waste segregation
Wastes from carbon black industry (air, water and solid) generate from several processes
(Figure 9). They can be segregated as describe in Table 4.
PWW3
Raw water
Carbon feed
stock storage
Water
treatment
Combustion
Reactor
Vent gas 1
Bag house
filter
Boiler
Off gas
Vent gas 2
Pelletizers
SWP1
Steam
Blow down
water
PWW2
SWP3
Pneumatic
conveyer blower
Dryer
Packaging
Carbon black
Spill &
leakage
Fugitive
PM
Flue gas
SWP2
Ground
washing
PWW1
Figure 9 Schematic diagram of waste from carbon black process
Note: PWW = Process wastewater
SWP = Solid waste from process
PM
= Particulate matter
12
Table 4 The segregation of wastes in carbon black process
Waste
Waste Air
Off gas
Flue gas
Fugitive particulate matter
Sources
Vent gas1
Vent gas 2
Oil reactor
Wastewater
Domestic wastewater
PWW1
PWW2
PWW 3
Solid waste
General Garbage
SWP 1
SWP 2
SWP 3
Management
Recycle for steam making
Sent to boiler
Sent to central vacuum system
and disposal
Reduce pollution by dry
scrubber
Reduce pollution by wet
scrubber
Treated by septic tank and
aerobic biological process
Treated by Physico-chemical
process
Reuse in office and canteen
13
-
SO2 (ppm)
Location
Inside the plant, 2
km. and 5 km.
from the plant
As above
NOx (ppm)
CO (ppm)
As above
As above
Maximum Value
100-120
Standard
240
400
950
80
1,500
200
690
14
Table 6 The parameters for water sample
Parameters
pH
Temperature
SS
TDS
BOD
COD
Oil and Grease
Location
Discharge of WWTP
Discharge of WWTP
Discharge of WWTP
Discharge of WWTP
Discharge of WWTP
Discharge of WWTP
Discharge of WWTP
Maximum Value
6-7.5
< 40C
50 mg/L
2,800 mg/L
15 mg/L
120 mg/L
4.5 mg/L
Standard
5.5-9.0
40C
Not exceed 50 mg/L
Not exceed 3,000 mg/L
Not exceed 20 mg/L
Not exceed 120 mg/L
Not exceed 5.0 mg/L
9.1.4 Monitoring
The frequency of environmental monitoring is shown in table 7.
Table 7 The monitoring program and frequency
Environmental media
1. Discharge of WWTP
2. Surface water
3. Air
4. Sediment
Monitoring frequency
4 times/month
1 time/month
1 time/month
1 time/month
Input
Manufacturing
Process
15
10. Conclusion
Carbon black is the product from incomplete combustion of petroleum product. The
major environmental problems of carbon black industry are air pollution, water pollution,
solid waste and noise pollution. The manufacturing processes of carbon black mostly rely
on high temperature and incomplete combustion. Then air pollution generated from the
process mostly are particulate, sulfur dioxide, oxides of nitrogen and carbon monoxide.
The wastewater generated from the process has high temperature and contains particulate,
suspended solid, total dissolve solid, BOD, COD and oil/grease. The solid wastes
generation consist of pallet, paper, plastics and polypropylene bags from process and
packaging; domestic waste from office and canteen; carbon black residue from
wastewater treatment plant.
In this report, waste abatement and cleaner production of the carbon black process has
been propose to reduce major generated pollutants. New equipment such as dry scrubber
would be installed to reduce air pollution emission from steaming process. Fugitive
particulate matter (mostly carbon black) will be collected and recovery. For domestic
wastewater, aerobic biological treatment would be added. Waste segregation and process
modification will be used in cleaner production strategy.
16
References
http://www.carbon-black.org/what_is.html
http://www.co2management.org/proceedings/Yoshitaka_Paper_on_Carbon_Black_Man
ufacturing.pdf
http://www.encyclopedia.com/doc/1G1-16860840.html
http://www.epa.gov/ttn/chief/ap42/ch06/final/c06s01.pdf
http://gestdoc.webmichelin.com/repository/DocumentRepositoryServlet?codeDocument=
1922&codeRepository=MICHCORP&codeRubrique=FB_01_EN
http://www.pcd.go.th/info_serv/en_reg_std_airsnd03.html
http://www.pcd.go.th/info_serv/en_reg_std_water04.html#s1
http://www.pcd.go.th/info_serv/en_reg_std_airsnd03.html
http://www.the-infoshop.com/study/fd29486_carbon_black.html
http://www.thermaxindia.com/v2/DivAdmin/Downloads/images/carbon%20black_Enviro
.pdf
http://www.unep.fr/pc//cp/understanding_cp/related_concepts.htm