Detailed Project Report (DPR) on Carbon Black from Feedstock (Capacity: 36 MT/Day)

CARBON BLACK FROM FEEDSTOCK

[EIRI/EDPR/4580] J.C.: 2797XL

INTRODUCTION

The term C-black refers to finally divided carbonaceous Pigments which are derived from pyrolyrish & hydrocarbon gas and oils. Depending upon method of manufacture carbon black may classified into five principal types-lamp black, channel or impigment carbons, thermal blacks, acetylene black and furnace carbon.

The two properties of Carbon black that are most important in commercial applications are particle size and high surface area. Particle size ranges from 100 to 5000 0A & surface area falls within range from 6 to 1,100 m2/gm. Actual C content will vary 83 to 99%. The arrangement of carbon particles may be described as comprising hexagonal nets of carbon atoms, par crystalline in nature. When viewed with an electron microscope particles appear as rough sphere, although they usually are seen in clusters rather than as individual spheres. The aggregating or clustering behavior of C black is considered to be result from physical and chemical bording effects. The manufacturing of Carbon black requires careful monitoring and control over surface area and particle size and because of wide range of control parameters a wide spectrum of C blacks can be created for varying requirements.

The human eye can distinguish 260 shades of blackness. The blackest carbon particle of the commercially available type will have a diameter of about 1000A, whereas greatest particle will have a diameter of approximately 50000A. The blackness of carbons often is referred to as measure those particles having the smaller diameters and great surface areas exhibiting the highest master.

Carbon black is a black fluffy material hence it creates lot of typical handling problems. The workers in plant should be provided with adequate protection against contamination due to inhalation of fumes of powder. Carbon black refers to powder product deposited by contact of flame on the metallic surface.

C black is of very plocculent nature whereas carbon black differs in structurally that carbon black is mainly crystalline with some ommosphons particles blended in it. It is well known that carbon particles have been the cause of luminosity of flames. Scot is formed in luminous planed and it can be collected even through non- surety flame by passing a cold probe through luminous zone. In same way formation of C black in the channel and furnace processes involves the liberation of C particles form flames although in some processes such as thermal the flame is not directly involved. However in both cases carbon is produced by thermal decomposition of hydrocarbons.

COST ESTIMATION

Plant Capacity            36 MT/Day  

Land & Building (10,000 sq.mt.)    Rs. 5.05 Cr    

Plant & Machinery                    Rs. 12.00 Cr 

Working Capital for 1 Month    Rs. 7.01 Cr 

Total Capital Investment          Rs. 24.75 Cr 

Rate of Return                          32%

Break Even Point                      51%

CONTENTS

INTRODUCTION

CARBON BLACK FEEDSTOCK

PRODUCTION

END USE

MARKETING ARRANGEMENT

TECHNICAL SPECIFICATION OF CARBON BLACK FEEDSTOCK

AVAILABILITY OF RAW MATERIAL

B I S SPECIFICATIONS

FAST EXTRUSION FURNACE (FEF) CARBON BLACK

1. SCOPE:-

2. REQUIREMENTS:-

3. PACKING & MARKING:-

4. SAMPLING:-

TABLE-1: REQUIREMENTS FOR FAST EXTRUSION FURNACE (FEP) CARBON BLACK

IS: 7497-1974 SPECIFICATION FOR HIGH ABRASION FURNACE (HAF) CARBON BLACK

1. SCOPE:-

2. REQUIREMENTS:-

TABLE -1: REQUIREMENTS FOR HAF CARBON BLACK

3 PACKING & MARKING:-

4 SAMPLING:-

IS: 8134-1976 SPECIFICATION FOR INTERMEDIATE SUPER ABRASION FURNACE (ISAF) CARBON BLACK

1. SCOPE:-

2. GRADES:-

3. REQUIREMENTS:-

4. PACKING & MARKING:-

5. SAMPLING:-

TABLE-1: REQUIREMENTS FOR INTERMEDIATE SUPER ABRASION FURNACE (ISAF:) CARBON BLACK

IS: 40-1971 SPECIFICATION FOR CARBON BLACK FOR PAINTS

1. SCOPE:-

2. TERMINOLOGY:-

3. CLASSES & TYPES:-

4. REQUIREMENTS:-

5. BACKING & MARKING:-

TABLE -1: REQUIREMENTS FOR CARBON BLACK FOR PAINTS

6. SAMPLING:-

7. TEST METHODS:-

8. CRITERIA FOR CONFORMITY:-

IS: 7498-1974 METHODS OF SAMPLING AND TEST FOR CARBON BLACK

1. SCOPE:-

2. SAMPLING:-

TABLE -1.: NUMBER OF BAG'S TO BE SAMPLED

3. QUALITY OF REAGENTS:-

4.1. APPARATUS:

5. IODINE ABSORPTION NUMBER:-

6. DIBUTYL PHTHALATE ABSORPTION (DBP):-

7. POUR DENSITY:-

8. SIEVE RESIDUE:-

9. LOSS ON HEATING:-

10. ASH CONTENT:-

11. ACETONE EXTRACT EXTRACT :-

12. STAINING TEST:-

14. SULPHUR CONTENT:-

15. PH VALUE:-

USES AND APPLICATIONS

APPLICATIONS OF MAJOR RUBBER GRADE CARBON BLACKS

EFFECTS OF CARBON BLACK COLLOIDAL CHARACTERISTICS ON RUBBER PROCESSING & PHYSICAL PROPERTIES

TYPES OF CARBON BLACKS

STRUCTURE:-

PRINTING INIKS:

PAINT, LACQUERS, ENAMELS & INDUSTRIAL FINISHES:-

PLASTICS:-

PAPER:-

OTHER APPLICATIONS:-

TYPES OF CARBON BLACKS

PROPERTIES OF CARBON BLACK

SIEVE RESIDUE:

PARTICLE SIZE:

FIGURE: CARBON BLACK PARTICLE SIZE COMPARISON

STRUCTURE:

FIGURE: CARBON BLACK STRUCTURE

SURFACE AREA:

SURFACE CHEMISTRY:

POROSITY:

AGGREGATE SIZE:

AGGREGATE SHAPE:

MARKET OVERVIEW OF CARBON BLACK

CARBON BLACK MARKET TRENDS

INCREASING APPLICATION OF TIRES AND INDUSTRIAL RUBBER PRODUCTS

CHINA TO DOMINATE THE MARKET IN THE ASIA-PACIFIC REGION

CARBON BLACK MARKET LEADERS

PRODUCTION OF CARBON BLACK

EXPORT OF CARBON BLACK

CONSUMPTION OF CARBON BLACK

IMPORT OF CARBON BLACK

MANUFACTURING PROCESS OF CARBON BLACK

MANUFACTURING PROCESS HAS THE FOLLOWING SECTION:-

MANUFACTURING PROCESS IN DETAILS

CLASSIFICATION OF CARBON BLACK MANUFACTURING PROCESSES:

TABLE: KINDS OF CARBON BLACK MANUFACTURING PROCESSES

FURNACE BLACK METHOD:

FIGURE: SCHEMATIC DIAGRAM OF THE INDIVIDUAL PROCESS STEPS IN A CARBON BLACK PRODUCTION UNIT

FIGURE: INTERNAL DIAGRAM FOR THE FURNACE BLACK PROCESS

LAMPBLACK PROCESS:

FIGURE: LAMPBLACK PROCESS

CHANNEL BLACK PROCESS:

FIGURE: CHANNEL BLACK PROCESS OR GAS BLACK PROCESS

THERMAL BLACK PROCESS:

FIGURE: THERMAL BLACK PROCESS

ACETYLENE BLACK PROCESS:

FORMATION MECHANISM:-

A MODEL REACTION MECHANISM OF CARBON FORMATION INVOLVES SEQUENTIALLY:-

HEALTH AND SAFETY ASPECTS

BASIC PROCESS OF CARBON BLACK

FURNACE BLACK PROCESS EQUIPMENT:-

TABLE: TIME- TEMP. CONDITION IN CARBON BLACK REACTORS

REACTORS:

POST RECTOR PROCESSING:

(II) THERMAL BLACK

FLOW DIAGRAM FOR CARBON BLACK MANUFACTURER

III. CHANNEL BLACK:-

FROM NATURAL GAS (CHANNEL PROCESS)

PROCESS:-

IV. ACETYLENE BLACK:-

ADDRESSES OF PLANT & MACHINERY SUPPLIERS

ADDRESSES OF PLANT & MACHINERY SUPPLIERS (IMPORTED)

ADDRESSES OF RAW MATERIALS SUPPLIERS

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)