carbon black manufacturing in Continental carbon india ltd ghaziaabad. one month summer training report.

1. SUMMER TRAINING REPORT (JULY-2013)
ON
MANUFACTURING OF CARBON BLACK
IN CONTINENTAL CARBON INDIA LIMITED,
GHAZIABAD, (UP)
Dr. K N Modi Institute Of Engineering & Technology,
ModINAGAR, GHAZIABAD, U.P
Prepared BY:-
Sunder Singh jeena

2. COMPANY - ABOUT CCIL

3. CONTINENTAL CARBON INDIA LTD
Continental Carbon India Limited (CCIL) was formed in
October 2000 upon the acquisition by Continental Carbon
Company (CCC), USA of the carbon black assets of Oriental
Carbon & Chemicals Ltd. Since then the carbon black
manufacturing facility in Ghaziabad, in the state of Uttar Pradesh,
has been substantially refurbished and production capacity
doubled to 85,000 MT/ Annum. A 15 MW Waste Heat Recovery
Power Plant, commissioned in 2008 is co-located with the
manufacturing unit and supplies power to the Uttar Pradesh grid.
Continental Carbon Company, USA which is recognized as a
leader in the development and manufacture of furnace grade
carbon blacks has licensed leading edge and environmental
friendly manufacturing technology to CCIL.

4. PRODUCTS

5. CARBON BLACK

6. BY-PRODUCT
High Pressure Steam
Power - Electricity

7. ABOUT CARBON BLACK
Carbon black is
a quasi-graphite
form of elementary
carbon fused
together in a grape
like agglomerate
structure.

8. PRODUCTION PROCESSES
 Lamp Black Process
 Channel Black Process
 Furnace Black Process
 Thermal Black Process

9. Continental Carbon India Ltd is
manufactures Carbon Black through
The Furnace Process using
technology licensed from
Continental Carbon Company, USA.

10. RAW MATERIALS FOR CARBON BLACK
1. CBFS (carbon black feed stock)
 Coal tar distillates
 Petroleum oils (Aromatic Concentrates)
 Steam cracker oils
 Naptha
 Coal Tar oil
 Mixed oils
2. FUEL OIL
 LDO (Light Diesel Oil)
 Furnace Oil
3. POTTASSIUM
4. MOLASSES

11. CARBON BLACK
PRODUCTION PROCESSES
Carbon black is produced by
incomplete controlled combustion of
high molecular wt. aromatic hydrocarbon
by thermal cracking. The reaction occur
is semi-pyrolysis thermal decomposition
of hydrocarbon.

12. Main Reaction Occur In Furnace Black
Process :-
 COMBUSTION
CnH2n + x + (3n/2 + x/4)O2  nCO2+ (n+x/2) H2O + Energy
 CRACKING
CnH2n + x + Energy  CnHb + (n+x/2 - b/2)H2
[ n >=b ]
 SYNTHESIS
CnHb  nC + b/2H2

13. The Complete Manufacturing Process has
the Following Sections:-
1. Feedstock storage and pumping
2. Reactor section
3. Bag filter section
4. Pelletisation and drying section
5. Conveying and storage section
6. Packing and dispatching section

14. 1. FEEDSTOCK STORAGE AND PUMPING
Carbon black feed stock is stored and shipped in
a completely closed system.
In CCIL vendor for cbfs are reliance Jamnagar,
IOCL barauni by whom oil are imported by rail wagon or
tank truck. And through transfer pump it stored in large
cylindrical storage tank.

15. Water spraying to stop the rexn
The process starts with the pre-heating of feedstock oil,
passing it through a high-temperature, fuel-fired chamber .
The reaction zone temperature is maintained at 1300 ◦c. And
water is spread in certain distance of reactor to stop the
reaction.
In this chamber, feedstock oil is subjected to carefully
controlled time and temperature parameters, turning
the oil into a high-temperature vapor stream containing
carbon black molecules.

16. FLOW SHEET FOR
CARBON BLACK
MANUFACTURING:-

18. BAG FILTER SECTION
This vapor(smoke) exits the reaction chamber( that
smoke generated during combustion of the feedstock is a
mixture of active carbon & combustible gases) is passes
through APH( air pre heater) and OPH( oil pre heater) to
transfer its heat energy.
Next it enters to the bag filter house. The smoke is
filtered in a bag house fitted with multiple filter bags
arranged in different compartments.
Carbon black gets separated from the combustible
gases. By mean of filter media( i.e. bag filter) the carbon
black molecules are captured and separated from the
gas.
This combustible gas is send to drier combustor and
WHRPP( waste heat recovery power plat) for steam &
power generation.

19. PELLETISATION AND DRYING SECTION
Meanwhile, carbon black molecules
collected in the bag filters are automatically
shaken off of the bags and pulled by gravity into
a collector pipe, where they are directed into a
pelletizer. There, the molecules are combined
with a fine moist of water-molasses solution to
create small, uniform beads of carbon black
product.
The pellets are fed through a natural gas-
fired dryer to achieve a moisture content of less
than one-quarter of one percent,

20. CONVEYING AND STORAGE
The dried material comes out is
conveyed to silo storage tank through mean
of bucket elevator n screw conveyor.

21. PACKING
Then piped into bulk storage, awaiting
shipment to customers. Customers receive
carbon black from Continental Carbon in
individual poly or paper bags, Super Sacks
jumbo bags.

22. QUALITY CONTROL:-
CCIL has a well equipped laboratory for
characterization of carbon black grades.
Surface area of carbon black grades measured by
iodine absorption.
Structural anisometry of carbon black grades
measured by sophisticated absorptometerc with
DBP oil.
Tint strength of carbon black grades measured at
least once in every production run through using
ERICHSEN Tint Tester - 527.
Hardness of carbon black pellets is extensively
checked using Individual Pellet Hardness Tester
of HITEC – Luxembourg.

23. Depending upon the Surface Area,
Structure, Tint Strength, Pour Density, and
Rubber Properties of the pellets formed, various
grades of Carbon Black have been developed.

24. FUNCTIONALITIES OF CARBON
BLACKS
 Reinforcement
 Pigmentation
 Protection: UV, IR, Heat
 Electrical conductivity
 Catalyst support
 Reduction agent

25. APPLICATION DOMAINS :-
 Rubber
 Plastics
 Inks and paints
 Conveying belt & v-belt.
 High Voltage Cable
 Batteries & Energy
storage.
 Li-ion batteries
 Supra-capacitors

26. APPLICATION DOMAINS

27. ANY QUERIES
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28. Thank You…