PROCESS FOR MANUFACTURING CARBON BLACK AND THUS MANUFACTURED CARBON BLACK

Abstract: Method for manufacturing carbon black, characterized in that one starts from an organic material, this material is compressed in a hydraulic press (1) subjected to a biochemical pre-processing in a magnetron (2) whereby a strongly increased activity of thermophicil bacteria and an acceleration of the gel formation of the binding protein plasm between the cells occurs, whereby a break-up of the organic cells takes place and one consequently subjects the obtained material to a pyrolysis in a reactor (4) comprising in the end a carbonising process.

Description: j. - PROCESS FOR MANUFACTURING CARBON BLACK AND THUS MANUFACTURED CARBON BLACK The invention relates to a method for manufacturing carbon black. Carbon black is often used as a filler or a reinforcement agent which is added to polymers, especially to rubber and elastomers. Carbon black is also suitable as a pigment for printing ink, coatings etc. Prior art methods for manufacturing carbon black start from hydrocarbons which are cracked and/or incompletely calcinated at high temperatures. Such methods are for instance described in the Dutch patent applications No. 8004048 and 8801112. As is started from hydrocarbons, at the used temperatures which may exceed 1000 degrees Celsius, products which are hazardous to the environment may possibly be created, such as PCB's and nitrosaminebearers. These products are thus found in the obtained carbon black. These products are mainly formed when starting from chlorinated hydrocarbons. The methods described in the above patent application principally aim at the obtaining of carbon black with more favourable characteristics, such as .a higher specific surface of the carbon black particles or a stronger structure whereby the carbon black is more appropriate for — _ — certain applications such as, for instance, the vulcanising of rubber. The present invention aims at a new method to manufacture carbon black whereby, in an economical and environmentally favourable way, a new kind of carbon black is obtained, presenting excellent and environmentally favourable characteristics, which is especially suitable as an additif to elastomers, printing ink and coatings and whereby the presence in the carbon black of hazardous products can easily be avoided. Therefore, one starts from an organic material, which is subjected to a biochemical pre-processing whereby a highly increased activity of thermophilic bacteria and an acceleration of the gel formation of the binding protein plasm between the cells occurs, whereby the break-up of the organic cells takes place, and one further subjects the obtained material to a pyrolysis which at the end comprises a carbonisation. In a special embodiment of the invention the pyrolysis is performed in at least three phases, wherein in a first phase, principally moisture, inclusive bound moisture is eliminated, and in a second phase, at higher temperature, principally evaporatable hydrocarbons and at last in a third phase, at still higher temperature, the carbonizing to carbon black of the remaining cell nuclei is executed. In a remarkable embodiment of the invention a pyrolysis is performed without oxidation agents. Such oxidation agents are for instance, air, which means that the pyrolysis is performed in an anaerobic way. - j - In an effective embodiment of the invention, the biochemical pre-processing comprises an irradiation with electromagnetic rays. Preferably the material is irradiated with magnetic wave pulses having a frequency between 800 and 1100 MHz. In a preferred embodiment of the invention, the pre-processing comprises a biochemical condensation of the starting material till the desired density and dry material content are reached. As a starting material, animal wasteproducts can economically be used or vegetable material or else algae, preferably so-called "blue green algae (cyanophites) " . T-.e invention also relates to the carbon black manufactured according to the method according to one of the above-mentioned embodiments. Other particularities and advantages of the invention will appear from the description hereinafter of a method for manufacturing carbon black and the thus manufactured carbon black, according to the invention. This description is on_.y given as an example and does not limit the invention. The reference numbers concern the attached drawing, which represents a block diagram of the procedure according to the invention. To manufacture carbon black having excellent characteristics one starts from or anic material in a relative solid form, having a dry dus content higher than 50%. Possibly a quantity of mineral material may be added to this organic material, but the quantity of mineral material has to be smaller than the quantity of organic material. As organic material are especially suitable animal waste products such as chicken manure and/or vegetable material and algae. Naturally, the quality and the characteristic of the obtained carbon black will be influenced by the composition of the starting material. This starting material is consequently subjected to a biochemical pre-processing and a pyrolysis. The biochemical pre-processing comprises a compacting in a hydraulic press 1 and an irradiation with electromagnetic waves in a magnetron 2. The compressing can be effected in several steps and by using smaller pistons which are mounted in the main piston and which can penetrate the mass compacted by the main piston, a homogenization of the material may be obtained. The compacting is performed using a pressure higher than 24,500 kPa and preferably higher than 27,440 kPa, but not higher than 29,400 kPa. A homogeneous mass is obtained, having a density equal to or higher than 280 kg per square centimeter power of resistance, and whereof the temperature is raised to 30-35 degrees Celsius and the moisture content decreased. The compacted homogeneous material is then irradiated in the magnetron 2 during at least 20 minutes and preferably about 30 minutes with electromagnetic pulses of, for instance 5 s with a frequency between 800 and 1100 MHz, and preferebly between 900 and 920 MHz. A magnetron having a power between 5 and 12 kW and preferably between 6,8 to 7,6 kW is used. Care is taken that the irradiation waves are evenly distributed upon the material. Therefore wave conductors may be used. Consequently the material is irradiated on top, underneath and on each side. The irradiation is performed in a poor air environment, and thus in an almost completely anaerobic way. The object of the irradiation is to activate specific anaerobic thermophilic bacteria such as for instance stearo-type bacteria which naturally present already a Brown movement. The frequency is thus selected that not so much friction between the molecules appears and consequently heating, as the activation of the Brown movement of bacteria and cell organisms. Therefore extreme care has to be taken to prevent the temperature of the material, because of friction between the molecules, to rise higher than 70 degrees Celcius. As a result of the activity of the anaerobic thermophilic bacteria, the temperature will also rise. On the other hand, the temperature may not remain at about 30 to 40 degrees Celsius, whereas, due to the activity of Psychro and Mesophyle bacteria, methane gas could be formed. The magnetron 2 is a closed tunnel. The material is moved through this tunnel by means of a conveyor belt, preferebly made from Teflon (registered trademark) or Keplar (registered trademark) . By the processing in the magnetron a biological analytic process of the organic material takes place and a strongly increased activity of thermophilic bacteria and an acceleration cf the gel formation of the binding protein plasm occurs, which entails a break-up of the organic cells. The material is decomposed by an increase of enzymes and plasma from the binding fibre structure and from the break-UD of the cells and cell nuclei. - D - The irradiated and already partially analysed material is crumbled in a device 3, whereupon the crumbled material is subjected, still without supplying oxidation agents and thus, among other things, without addition of air, and under an atmospheric pressure, in the reactor 4 to a pyrolysis comprising three phases. During the crumbling the released moisture is eliminated. During the first phase, in the first reactor zone 5, the incoming material having a temperature of about 70 degrees Celsius is heated to a temperature between 200 and 250 degrees Celsius whereby principally all the moisture, inclusive molecular bound moisture, is released. The released moisture is conveyed out of the reactor zone 5 and condenses in the condensor 8. The remaining material is heated in a second reactor zone 6 up to a temperature of approximately 480 degrees Celsius. Hereby most evaporatable hydrocarbons are released. Hydrocarbons which evaporate in this second zone are among other things unsaturated hydrocarbons such as ethylene and acethylene, alkenes such as ethene, propene and butene, aromatic hydrocarbons such as benzene, toluene and xylene and certain saturated hydrocarbons such as kerosines, naf alenes, ethylene tars. These released hydrocarbons are conveyed from the reactor zone 6 without their being in contact with the outflowing water and principally the gases which are released in the next reactor zone 7. The conveyed hydrocarbons are condensed in a condensor 9. The condensed hydrocarbons can possibly be used as fuel for the heating of the reactor zones. Finally, in the third reactor zone 7, the material is heated to a temperature of 520 to 580 degrees Celsius, preferably to 538 degrees Celsius and this material is kept at this temperature for 20 to 30 minutes and preferably 22 to 25 minutes. During this third phase a carbonization of the material occurs, these are the remaining cell nuclei, whereby carbon black is formed. The flowing through of the material from one reactor zone to the other is effected by means of mixture control screws and gas locks (so-called "air locks"). The gasses released during the last mentioned phase and among other things during the carbonizing process, are conveyed through 10. The obtained solid pulverised carbon black which is conveyed from the last reactor zone 7, still without supplying an oxidizing agent, is quenched or cooled. Possible unwanted by-products which might be present in the carbon black are separated. In the apparatus 12 the carbon black is possibly subjected to further post-processing such as sifting, grinding, degritting, ilutriating (separation) or the formation of grains or platelets or pellets. A new kind of carbon black is obtained with excellent characteristics which contain no products which are hazardous to the ivironment such as PCB's and nitrosaminebearers. Th s kind of carbon black presents the following characteristics: Absorption surface of iodine The absorption surface of iodine of the carbon black is determined as fellows: a carbon black sample is placed in a porcelain crucible, provided with a loose lid to enable the gasses to escape, and calcinated at a temperature of 927 degrees Celsius during 7 in. and afterwards cooled in an exsiccator. The top layer of the calcinated carbon black is removed to a depth of approximately 0,635 cm. A suitable sample is weighed from the remaining carbon black in the crucible. A sample of 0,1 g is suitable for carbon 2 black with an expected surface or 380 m /g. The sample is placed in a flask and fourty ml of 0,0473 N iodine solution is added. The flask is closed en shaken during 10 minutes at a speed of 120-260 up and down movements per minute. The obtained solution is immediately centrifugated at 1200-2000 rotations per minute until the solution becomes clear, this means mostly 1 to 3 minutes. A sample of 25 ml iodine solution, to which a few drops of a 1% starch solution as terminal indicator are added, is titrated with a 0,0394 N sodiumthiosulphate solution until the blue colour turns to colourless. As bianco sample 40 ml of the 0,0473 N iodine solution is shaken, centrifugated and titrated as described above. The iodine surface absorption S.A., is calculated as follows: S.A. = (10 B - 10 T - 4,57)/l,3375, wherein B represents the titration number of the sample to be measured. The carbon black manufactured according to the method described above, has an iodine surface higher than 380 m 2 /g. Dibutylphtalate absorption number (DBF) This is calculated according to the ASTM-testing method D2414-76. Palettized carbon black obtained according to the above method has a DBF value higher than 200 ml/100 g. PH The pH of a 5 g solution of the obtained palettized carbon black in 50 ml distilled water, boiled for 10 minutes, is measured. The pH is less than 5. Iodine addition number The iodine addition number of the carbon black according to ISO 1304 is 380 g/kg. Specific weight The specific weight of the obtained carbon black after ddrryyiinngg ffoorr 2244 hheours at 105 degrees Celsius in a pyrolitic Specific surface The specific surface measured with C0 adsorption at 273 K (compression modules) lies between 35 and 200 m 2/g, and 2 measured with N^ at 77 K between 10 and 30 m /g. Porosity Mercury porosimetry shows that also larger pores are present with rp=4-2000nm with a maximum of 4000 nm. These pores have a volume of Vp=0,3 - 0,7 cm /g. Size of the particles The diameter of the particles varies from 4 to 200 nanometer. The carbon black has a wide range of particle sizes. The d50 amounts to 51 micrometer. BET surface After being kept at 300 degrees Celsius during 16 hours, the BET surface measured with N adsorption at -196 degrees Celsius has a value of at least 34 m 2/g. Mixing behaviour The obtained carbon black is mixed with among other things ethylene-propylene-rubber (EPDM) , after being dried in a pyrolitic oven at 105 degrees Celsius for 24 hours, in a proportion of 70 parts of carbon black per 100 parts of polymer, in a Banbury-mixing device GK2 of Werner & Pfleiderer. Mixing conditions: loadfactor 76% revolutions rotors 46-48 rpm wall temperature: 40 degrees Celsius Mixing cycle: 0-30 s. polymer after 30 s. carbon black discharge after 3 min. 186,63 As a reference, the same mixture is manufactured but whereby the carbon black obtained according to the invention is replaced by a commercial carbon black, namely Cancarb Thermax carbon black. Both carbon blacks show a normal mixing behaviour. After the mixing, the mixtures are - 1 conveyed through a two roller grinding device and formed into sheets for further testing. Characterizing of the mixture carbon black carbon black (ref, ) (invention) ML (1+4) 100 C. 62,2 79,1 Rheometer 160 C. ML (Nm) 1,56 2,26 Ts2 (min) 1,35 1,20 T'c90 (min) 15,56 10,78 MH (Nm) 11,35 11,36 Vulcanisate 12 180 C. S 100 (N/mm 2 ) 2, 1, S 200 (N/mm 2 ) 4, 3, S 300 (N/mm 2 ) 5, 5 2 Tensile stress (N/mm ) 9, 8, Elastic strain at fracture (%) 415 367 Hardness (Shore A) 68 66 Compr. set 22 h/70C. 17 21 Compr. set 72 h/23C. 10 13 Conclusions From the preceding, it appears that the new carbon black obtained by the method described above is very satisfying for applications in rubbers and elastomers. The physical characteristics are easily influenced by modifying the conditions of the method within the determined limits and by the choice of the starring material. By th.s method carbon blacks can be manuf tured which can be classified according to the ASTM code from N110 to N990. Preferably carbon blacks are manufactured with a classification comparable to "medium thermal" . When applying the carbon black according to the invention in natural rubber and nitrile elastomer, the physical characteristics of the carbon black are comparable to these obtained with carbon black which is known on the market under the name THERMAX 991. The invention is by no means restricted to the above described method and carbon black, and within the framework of the invention many modifications may be made to the described embodiment.

Claims: Claims 1. Method for manufacturing carbon black, characterized in that one starts from an organic material, this material is subjected to a biochemical pre-processing whereby a strongly increased activity of thermophicil bacteria and an acceleration of the gel formation of the binding protein plasm between the cells occurs, whereby a break-up of the organic cells takes place and one consequently subjects the obtained material to a pyrolysis comprising in the end a carbonising process. 2. Method according to the above claim, characterized in that the pyrolysis is performed in at least three phases, whereby in the first phase principally moisture, inclusive bound moisture is released, and whereby in a second phase at higher temperatures principally evaporatable hydrocarbons are released by evaporation and whereby, finally in a third phase, at still higher temperatures, the carbonizing of the remaining cell nuclei to carbon black is performed. 3. Method according to the previous claim, characterized n that the first phase of the pyrolysis is performed at a temperature up to maximum 250 degrees Celsius. 4. Method according to one of the claims 2 and 3, characterized in that the second phase of the pyrolysis is performed at a temperature between 250 and 480 degrees Celsius. 5. Method according to one of the claims 2 to 4, characterized in that the third phase of the pyrolysis is performed at a temperature between 480 and 580 degrees Celsius. 6. Method according to one of the claims 2 to 5, characterized in that the third phase with the carbonization is performed during 20 to 30 minutes. 7. Method according to one of the above claims, characterized in that the pyrolysis is performed without oxidizing agents. 8. Method according to one of the above claims, characterized in that the biochemical pre-processing comprises an irradiation by electromagnetic rays. 9. Method according to the previous claim, characterized in that the electromagnetic irradiation is performed with wave pulses having a frequency between 800 and 1100 MHz. 10. Method according to the previous claim, characterized in that the electromagnetic irradiation is performed with wave pulses having a frequency between 900 and 1000 MHz. 11. Method according to one of the claims 8 to 10, characterized in that care is taken that, during the electromagnetic irradiation, the temperature of the material remains under 70 degrees Celsius. 12. Method according to one of the previous claims, characterized in that the biochemical pre-processing comprises a compacting of the starting material to the desired density and dry dust content. 13. Method according to the previous claim, charactirized in that the compacting is performed by compression with a pressure of 200 to 300 kPa. _ 1 I D - 14. Method according to one of the previous claims, characterized in that the biochemical pre-processing is performed without supplying oxidating agents and that, between the pre-processing and the pyrolysis, no oxidating agents are permitted. 15. Method according to one of the previous claims, characterized in that one starts from an organic material having a dry dust content higher than 50%. 16. Method according to one of the previous claims, charactarized in that animal waste products are used as organic material. 17. Method according to one of the claims 1 to 15, characterized in that vegetable material is used as organic material. 18. Carbon black manufactured according to the method according to one of the previous claims. 19. Carbon black according to the above claim, characterized in that it has a specific surface, measured 2 by C0 9 absorption, between 35 and 250 m /g, an iodide surface of at least 380 m 2/g, a pH lower than 5, a DBF-value higher than 200 ml per 100 g and a iodine addition number higher than 380 g per kg.

Inventors: SCHIPPERS WILHELMUS JOHANNES H, SCHIPPERS, WILHELMUS, JOHANNES, HENRICUS
Applicants: HEIJDEN IRIS DE PACE MARIA PAL, VAN DER HEIJDEN, IRIS DE PACE, MARIA, PALOMA
Application year: 1991
Main classification: C10B53
IPC codes: C09C1, C10B53, C10L9