Production of non-carcinogenic carbon black

Claim 2

A process for the production of a non-carcinogenic normal curing carbon black which comprises a. pyrolytically in a carbon black furnace decomposing a hydrocarbon feedstock having a low carbon residue of less than about 0.2 weight % such as to form smoke containing carbon black, b. severely aftertreating said smoke by subjecting it to at least one of the steps of late quenching and secondary air injection to produce a smoke containing a carbon black of about 100% photelometer and a pitting value of about 15 m 2 /g or more, in the case of a small particle carbon black having a CTAB surface of 120 m 2/g , of 7 m 2 /g or more for the carbon black having a CTAB surface area of 80 m 2 /g or more, and of 0.2 m 2 /g or more in the case of a large particle carbon black having a CTAB surface of 30 m 2 /g, said pitting value defined as the difference between the nitrogen surface area and the CTAB surface area, both in square meters per gram, c. separating said carbon black from said carbon black-containing smoke, d. oxidizing said carbon black and pelleting the carbon black with an aqueous pelleting agent, e. drying the wet carbon black pellets at a temperature of about 500° to 600° F, f. heat treating the dried carbon black pellets at a temperature in the range of about 1000° to 1400° F and thereafter recovering the dried carbon black pellets as the product of the process.

Claim 3

A process in accordance with claim 1 wherein said feedstock is selected from the group consisting of toluene and SO 2 extract oil.

Claim 4

A process in accordance with claim 1 wherein said carbon black is oxidized by contacting the carbon black with an aqueous solution of HNO 3 as the pelleting liquid so that the mixture contains about 2-10 wt. % of HNO 3 based on the weight of carbon black as 100%.

Claim 5

A process in accordance with claim 1 wherein said aftertreating of said carbon black-containing smoke is carried out by a late quench step and/or by the introduction of secondary air between the main carbon black forming reaction zone and a quench location.

Claim 6

A non-carcinogenic normal curing carbon black obtained by pyrolytically in a carbon black furnace decomposing a hydrocarbon feedstock having a carbon residue of less than about 0.2 weight per cent such as to form a smoke containing carbon black, severely aftertreating said smoke by subjecting it to at least one of the steps of late quenching and secondary air injection, separating said carbon black from said carbon black containing smoke, oxidizing said carbon black and pelleting said carbon black with an aqueous pelleting agent, drying the wet carbon black pellets at a temperature of about 500° to 600° F., heating the dried carbon black pellets at a temperature in the range of about 1000° to 1400° F., the thus obtained carbon black being further characterized by having a photelometer of 100 percent a pitting degree of about 15 m 2 /g or more in the case of a small particle carbon black having a CTAB surface of 120 m 2 /g, a pitting degree of 7 m 2 /g or more for a carbon black having a CTAB surface area of 80 m 2 /g and a pitting degree of 0.2 m 2 /g or more in the case of a large particle carbon black having a CTAB surface area of 30 m 2 /g, the minimum pitting degree of a carbon black having other CTAB surface areas being obtained by interpolation, said pitting value being defined as the difference between the nitrogen surface area and the CTAB surface area, both in square meters per gram, and a content of benzene extractables of less than 0.05 weight percent.

Claim 7

A non-carcinogenic normal curing carbon black obtained by pyrolytically in a carbon black furnace decomposing a hydrocarbon feedstock having a carbon residue of less than about 0.2 weight per cent such as to form a smoke containing carbon black, severely aftertreating said smoke by subjecting it to at least one of the steps of late quenching and secondary air injection, separating said carbon black from said carbon black containing smoke, oxidizing said carbon black and pelleting said carbon black with an aqueous pelleting agent, drying the wet carbon black pellets at a temperature of about 500° to 600° F., heating the dried carbon black pellets at a temperature in the range of about 1000° to 1400° F., the thus obtained carbon black being further characterized by having a photelometer of 100 percent a pitting degree of about 15 m 2 /g or more in the case of a small particle carbon black having a CTAB surface of 120 m 2 /g, a pitting degree of 7 m 2 /g or more for a carbon black having a CTAB surface area of 80 m 2 /g and a pitting degree of 0.2 m 2 /g or more in the case of a large particle carbon black having a CTAB surface area of 30 m 2 /g, the minimum pitting degree of a carbon black having other CTAB surface areas being obtained by interpolation, said pitting value being defined as the difference between the nitrogen surface area and the CTAB surface area, both in square meters per gram, and a content of benzene extractables of less than 0.05 weight percent.

Claim 8

A rubber composition consisting essentially of 100 parts by weight of a rubber selected from the group consisting of natural rubber and/or synthetic rubber and about 1 to about 200 parts by weight of a carbon black obtained by a process in accordance with claim 5.

Claim 9

A rubber composition in accordance with claim 6 containing about 20 to about 80 parts by weight of said carbon black.