CFD is employed to study and model the entire temperature distribution prior to introduction of combustion oils within the CB reactor. The application of CFD process involves solving or modeling flow equations consisting of five conservation equations of continuity, momentum and energy through a pressed based solution approach. Radiation models are also employed which consider radiation effects inside the high temperature process reactor. The combustion phenomenon is captured using different forms of combustion modeling techniques like non premixed combustion model along with chemical species modeling. For my blogs kindly refer: https://www.learncax.com/knowledge-base/blog/by-author/ganesh-visavale

1. Carbon Black : Reactor Analysis using powerful tool CFD
learncax.com /blog/2013/10/02/carbon-black-reactor-analysis-using-powerf ul-tool-cf d/
Ganesh Visavale
Comput at ional Fluid Dynamics (CFD) f or Carbon Black Manuf act uring
What is Carbon Black?
Carbon Black (CB) is a material produced by the incomplete combustion of heavy petroleum products such as FCC
(Fluid Catalytic Cracking) tar, coal tar, ethylene cracking tar, and a small amount of vegetable oil. It is a form of
amorphous carbon that has a high surface area to volume ratio majorly used as a pigment and reinforcement in
rubber and plastic products. CB is made in specially designed reactors operating at internal temperatures in the
range of 2600 F to 3600 F. Different grades of CB can be produced with varying aggregate siz e and structure and it
is these differences that allow CBs to be used in a variety of application.
Applicat ions of Carbon Black
CB is heavily used in manufacturing of rubber, plastics
and other products, the most common being (about
70%) as a pigment and reinforcing phase in
automobile tires. Carbon black also helps conduct
heat away from the tread and belt area of the tire,
reducing thermal damage and increasing tire life.
Carbon black particles are also employed in some
radar absorbent materials and in photocopiers and
laser printer toner, and other inks, paints also in
coloring of resins and films. It is also a common
material used for production of belts, hoses, and other
non- tire rubber goods.
How large is t he Carbon Black market ?
Total world production of carbon black was around 8,100,000 metric tons (8,900,000 short tons) in 2006. Worldwide
carbon black consumption is currently 9 million tonnes p.a.,expected to reach 13 million by 2015. Average global
growth will likely exceed 4% over the next five years, with China, India, and Central and Eastern Europe showing
much higher demand, while capacity will shift geographically to meet demand. Some of the big players in this field
are Philips Carbon Black, Sid Richardson Carbon Black Company, Continental Carbon Black Company and Birla
Carbon Black.
How is Carbon Black manuf act ured?
While there are several processes in which CB is made, among the common one is a furnace black process. In the
furnace black process aromatic oils (based on crude oil) or combustible gases are burned in a reactor, producing
carbon black and tail gas. After cooling, the CB is separated from tail gas, made more dense and processed into
pellets of varying grades/siz es. This process is currently the most widely used in the market.
Where does CFD come int o t he pict ure?
Use of Computational technology is required to maximiz e the efficiency of the CB manufacturing process as well to

2. reduce the environmental impact of CB production. Computational Fluid Dynamics (CFD) is used in the CB
manufacturing industry at various stages in the R&D cycle. CFD finds use in analyz ing or simulating the interaction of
liquids, gases and different surfaces within the manufacturing process inside the reactors. It is also used to model or
design auxiliary units like cooling jackets. CFD models have also been implemented to virtually visualiz e the
particulate siz es as well as combustion prior to introducing oil for CB production.
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How is CFD employed f or design of CB react or?
The valuable information a CFD model provides can be utiliz ed to come up
with most efficient CB manufacturing process with minimiz ed environmental
effects
CFD is employed to study and model the entire temperature distribution prior
to introduction of combustion oils within the CB reactor. The application of CFD
process involves solving or modeling flow equations consisting of five
conservation equations of continuity, momentum and energy through a
pressed based solution approach. Radiation models are also employed
which consider radiation effects inside the high temperature process reactor. The combustion phenomenon is
captured using different forms of combustion modeling techniques like non premixed combustion model along with
chemical species modeling. Various commercial software have capabilities involving these above models and they
can be efficiently used if an engineer possess the modeling skills. Using virtual computational environment CFD can
help design engineers visualiz e velocity, pressure, temperature and chemical species distribution at various
locations and during different stages of CB manufacturing process. The valuable information a CFD model provides
can be utiliz ed to come up with most efficient CB manufacturing process with minimiz ed environmental effects.
CCTech expert ise in t he area of CFD f or Carbon Black
CCTech has established expertise in using CFD at various level of the Carbon Black manufacturing process.Our
CFD based design studies have helped our valuable customers to make inroads into efficient equipment and
process design for CB manufacturing. Some of the areas we have expertise in are listed below:
Our CFD based design studies have helped our valuable customers to make inroads into efficient equipment and
process design for CB manufacturing
Applying combustion modeling techniques to simulate combustion of air- gas mixture
Particulate modeling inside CB reactor
Flow modeling to study flow behaviour
CFD modeling of auxiliary equipment like cooling jackets, inlet routes
CFD modeling of mixing inside CB reactor
Expertise in application of commercial software like FLUENT, STAR CCM+, ICEM, Comsol to simulate different
process inside CB reactor.
If you have any more questions on this article or if you are interested in any work and have any work requirement in
the area of CFD for carbon black please feel free to write us at: info@learncax.com
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