INNOVATION | CARBON BLACK


hydrocarbon) levels. This, among other things, enables them to be used for products that come into direct contact with foods in Europe (he says restrictions on such applications are tighter in the US). Particle size distribution is also very consistent and ash content variation is in the range of ±0.5%, which he claims is around one order of magnitude less than some rivals and is a critical attribute for obtaining consistency in masterbatches. Cremer also says that NEPtune grades have slightly different particle surface characteristics, which makes them both easier to disperse and slightly less polar than traditional blacks. With a Hansen solubility parameter of around 2, compared with anywhere from 8 to 14 for regular furnace blacks, NEPtune grades cannot be used as drop-in substitutes for existing carbon blacks. The materials are also non-conductive so may need to be modified for applications such as cable compounds.


Treading carefully


Below: Old tyres are the feedstock for the recycled carbon black industry but must be


selected with care


Despite the world being seemingly awash with old tyres that offer potential for conversion to rCB, Cremer says the considerable variability in tyre formulations means it has to be very careful in selecting its feedstocks. Depending on the tyre type (whether formulated for road or agricultural use, for example), the silica levels can vary substantially. It currently obtains its feedstock material from Kargo, the largest tyre recovery company in the Benelux region of Europe, which supplies it with rubber that has already been separated from its metal or synthetic fibre reinforcement. Black Bear currently has a pilot facility at Nederweert in the Netherlands, although it is currently out of commission following a fire there in February of this year. Compounding World understands that the company will shortly announce commercial-scale facilities for the same country and also in Germany; it is currently seeking debt and equity finance. These new facilities are likely to have capacities to produce around 12,500 tonnes/yr of rCB, which means that they will process 31,000 tonnes of tyre granulate annually (the balance being converted into oil and gas). Black Bear is also in discussions with potential licensees for its technology in other countries. Swedish company Enviro Systems is also active in the tyre pyrolysis sector and already has a plant converting around 6,000 tonnes/yr of tyres into rCB


and pyrolysis oil at Åsensbruk. The company is currently targeting applications in rubber more than plastics and is also looking toward plant sales and joint ventures outside Sweden. It is currently finalising an agreement with TreadCraft Carbon of Buffalo in New York State, US, to establish a jointly owned plant in the country. Enviro Sales Manager Fredrik Olofsson says a


problem with making rCB suitable for plastics applications is that in many cases where good blackness is required, ash levels of around 0.5% are needed. This is possible with conventional carbon black but is challenging with rCB, he says. Without special, and costly, treatments rCB has ash contents of upwards of 10% and can frequently exceed 20% if no tyre pre-sorting is employed. Meanwhile, Munich-headquartered Pyrolyx said last month that it had completed “cold commissioning” of the major systems at its recently constructed plant for producing rCB from used tyres at Terre Haute, in Indiana in the US. Cold commissioning is the full operation of machinery and systems and is carried out in preparation for hot commissioning and initial production, which the company says should begin soon. Pyrolyx recently acquired J&R Used Tire Service, which has a tyre processing facility 45km from Terre Haute. It also has a plant at Stegelitz in Germany and is planning a third plant, which will be located in the east of Europe and could go into operation in late 2021. Canadian company Klean Industries, which is


based in Vancouver, says it is already producing several grades of carbon black for use in rubber and—to a lesser extent—plastics. It claims that it is “currently the only supplier to our knowledge that is capable and is providing rCB carbon materials directly back in new tyre and retread tyre manufac- turing processes globally.” It also says that its Klean Carbon CBk carbon blacks are widely used for various masterbatch applications. Klean Industries also sells equipment for


producing carbon black from old tyres using its CBk proprietary process. It describes this as a post-processing method and technology platform that can significantly modify and improve the


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COMPOUNDING WORLD | November 2019 PHOTO: BLACK BEAR CARBON


www.compoundingworld.com


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