CONTINENTAL CARBON

Presented at Carbon Black Conference 2017 at Chennai by A. P Abraham

1936

First CB Plant at Sunray,Texas

1954

Second CB Plant at Ponca city

1955

Pilot plant Sunray,Texas

1969

Third CB Plant at Phenix city

1990

Expansion at Ponca city

1969

Expansion at Phenix city

2000

Acquired OCCL and it become CCIL

Increase Stress-Strain

Properties

Increase Abrasion

resistance

Increase Service life/reduce

Compound Cost

INPUT PROCESS OUPUT

People

Educated

Experienced

Skilled

Trained

Information

Clear

Accurate

Timely

Material

Quality

Quantity

Equipment

Suitable

Maintained

Method Control Resources

Products

Services

De

fin

ed

Ava

ila

ble

Co

mp

lied

Pa

ram

ete

rs

Eq

uip

me

nts

Mo

nit

ori

ng

Ava

ila

ble

Op

tim

um

Quality

OK

NOT OK

Cost

Reasonable

Expensive

Speed

In time

Too early

Delayed

Control Out put by adjusting Input & Process Control through Problem solving / or Process Improvement

Feedstock

Petro-Chemical

Carbo- Chemical

Meet stringent quality requirements of customers at optimum cost.

The availability of Quality consistent Raw material.

Technological innovations to improve Product quality irrespective of input material quality.

Meeting the end Product quality expectation of customers

As mentioned earlier Carbon black enhances the properties of elastomers by improving its mechanical Properties such as abrasion resistance or the fatigue life. In order to design a product and understand the properties of filled elastomers used in industry; it is important to understand the effect of raw material used for the production of Carbon black.

There is a common belief that Carbon black

Produced with Petroleum based (FCC oil) gives better mechanical properties.

The chemical and Mechanical Properties of filled Natural rubber compound with N220( ISAF) produced with different feedstock type. It is of the interest to know how the differences in feedstock impact the physical properties of the vulcanisate.

Characteristics UoM Spec Test method Feedstock

FCC CT

Specific Gravity @15.56°C gm/cc 1.08 Min WI:QA:FS:02 1.08 1.14

API Gravity - .48Min WI:QA:FS:04 0.99 -7.3

Viscosity@ 98.9°C SUS 115 Max WI:QA:FS:03 89 56

BMCI 120 Min WI:QA:FS:04 126 167

Sulphur Content wt % 1.5 Max WI:QA:FS:08 0.80 0.49

Water Content Vol % 1.0Max WI:QA:FS:01 0.2 0.5

Process Conditions of N220 Production kept same for both the feedstock except the Nozzle angle , atomising media and its conditions.

The compounding formulations (in weight per hundred weight of rubber(phr) used in this work are listed below. The mixing or compounding of Natural Rubber and other additives was carried out in two roll lab mixing mill as specified in ASTM D 3192. Sample I Sample II

Natural Rubber ISNR 3 CV 100.0 100.0

Carbon Black 50.0 50.0

ZnO 5.0 5.0

Stearic Acid 3.0 3.0

MBTS 0.6 0.6

Sulphur 2.5 2.5

Horiba make Laser Scattering Particle size distribution Analyser used to evaluate the Aggregate size distribution of N220 Produced as per the Process conditions mentioned above

The Aggregate Particle size of Sample I & Sample II is illustrated below.

0

2

4

6

8

10

12

14

16

0.0

51

0.0

67

0.0

87

0.1

15

0.1

5

0.1

97

0.2

59

0.3

39

0.4

45

0.5

84

0.7

66

1.0

05

1.31

8

1.72

9

2.2

69

2.9

76

3.9

05

5.12

2

6.7

2

8.8

16

Q %

Diameter µm

Particle size distribution of N-220

FCC

CT

The identical ASD curve was a result of Process modification and fine tuning of the reactor operating conditions to produce comparable product with different type of oil. The ASD data shows that the difference in particle size distribution is not significant. The BET value also supports this finding.

The rheometer, a convenient instrument to evaluate the effects of carbon black rubber interactions on rate of cure, was employed for the purpose of characterizing critical parameters related to the vulcanization process.

RHEOLOGICAL PROPERTIES @145 Deg C

Parameters UoM CT FCC

a. ML N-m 14.68 13.53

b. MI N-m 19.9 22.69

c. TC90 mm:mm 19.87 20.76

d. MH N-m 63.91 62.39

e. TS2 mm:mm 2.34 3.23

f. MH-ML (∆M) N-m 49.23 48.87

As illustrated in Table IV. N220 Produced with CT shows slightly fast cure with respect to FCC.

The heat build up and Abrasion loss were measured for the N220 samples. The results are tabulated in Table V. Lab facility of HASETRI has been used to determine these properties

It has been observed that N220 Produced with CT shows better result with respect to FCC oil.

In this study, the Physio-chemical Properties of Carbon black N-220 Produced with two different feedstock, namely FCC oil and Coaltar oil were investigated. The chemical and mechanical properties of both the black were measured. The experimental results show good co-relation in aggregate particle size distribution of N220 Produced with coal tar as feedstock after Process modifications.

The analysis result shows that the impact of difference in feedstock type can be technically resolved by improving the Carbon black Production process control. It further validate that with the technological advancement, carbon black industry can produce consistent product irrespective of input material.

My sincere thanks to Management of Continental carbon for providing all assistance to conduct this study and give their permission to publish this paper in Carbon black conference 2017.