Emergence of Conductive Carbon Black
Furnace black is a material produced by the incomplete combustion of heavy petroleum products such as FCC tar, coal tar, ethylene cracking tar, and a small amount from vegetable oil. It was discovered in early 1800s when printers observed that oil residues from lamps darkened paper. The commercial manufactures of conductive carbon black started in Germany in 1860. Since then, furnace black production has risen exponentially due to its widespread applications. Today, furnace black Industry produces over 11 million tons of furnace black annually across the world.
Uses of Conductive Carbon Black
Furnace black finds extensive usage as a reinforcing filler in the elastomer industry. Over 90% of total furnace black produced is used in the tire sector for manufacturing tires. As a reinforcing filler, furnace black improves tire strength and durability. Other qualities significantly enhanced are resistance to wear and tear, improves traction in wet conditions.
Apart from tires, furnace black is also used as a pigment and reinforcement in hoses, belts, cables, and other molded and extruded rubber goods. It serves to impart color and mechanical strength to the products. Furnace black is a key material for industrial rubber products used across automotive, oil and mining industries.
Another major application is as a color pigment in inks, paints, and plastics. Conductive Carbon Black provides durability, weather resistance and opacity to end products. About 5-6% of total production goes into printing and packaging inks. Plastics like PVC pipes also utilize furnace black as a reinforcing agent and enhancer of electrical and thermal conductivity.
Emerging Applications
With advancing technologies, furnace black finds new applications as well. One promising avenue lies in the energy storage sector. Furnace black combined with other materials forms a key component in lithium-ion batteries employed in devices and electric vehicles. This improves battery capacity and longevity.
Furnace black polymer composites also have potential in electromagnetic interference (EMI) shielding. EMI shielding helps block out radiation and wireless signals. Such materials find increasing demand in electronic equipment.
Additionally, furnace black helps remove impurities from flue gases and improves fuel efficiency in diesel engines. This addresses issues related to vehicular pollution. Overall, furnace black's unique properties enable its versatile integration across automotive, energy, packaging and construction industries.
Production Techniques
The predominant production method involves the cracking of oil or natural gas in an oxygen-starved environment. During this thermal decomposition or pyrolysis process at high temperature, around 1400°C, the fossil fuels break down into furnace black along with other residual gases.
The commonly deployed manufacturing techniques are furnace black, thermal black, and channel black processes. Furnace black utilizes oil or gas feedstock in regeneration furnaces with multiple process chambers. Thermal black utilizes nozzles to spray feedstocks in closed coupled reactors having concentric tubes.
Channel black also employs nozzle spray but has multiple stacks of externally heated straight pipes without recirculation. The technique produces extremely fine grades of furnace black. Stringent quality control and monitoring during manufacturing ensures furnace black properties match end application needs.
Future Outlook
Asia Pacific leads in furnace black backed by robust demand from China, India and other developing nations. This region accounts for over 50% of global furnace black production due to vast manufacturing hubs, emerging economies and growing vehicle ownership. North America and Europe also have established s.
The furnace black is forecast to reach $20 billion by 2025 driven by rapidly rising polymer and tire industries coupled with new furnace black applications. However, global efforts towards sustainability may impact long-term demand or prompt shift towards greener production methods. Overall, furnace black's unique blend of properties guarantees continued importance as an industrial material.
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