Energy efficient process for the production of carbon black

Claim 1

A method of operating an elongated, generally cylindrical reactor having an upstream and downstream end for the production of carbon black by the furnace process wherein the combustible gases generated a pyrolytically dissociating a carbon black producing feedstock are cyclically utilized as the fuel for effecting the dissociation reaction, which comprises: introducing a hydrocarbon fuel together with a 25-75% stoichiometrical excess of oxidant gas containing at least 70 volumetric percent oxygen into the upstream end of said reactor and substantially completely burning the fuel to provide a turbulent mixture of combustion gases; injecting a normally liquid aromatic-rich hydrocarbon feedstock into said turbulent mixture of combustion gases and burning said feedstock to the extent provided by the presence of free oxygen in the combustion gases while essentially simultaneously effecting the pyrolytical dissociation of the unoxidized portion of the feedstock to generate a carbon black aerosol; quenching the pyrolysis reaction and discharging the aerosol from the downstream end of the reactor whence the carbon black is recovered by filtration; continuously maintaining the production of carbon black in the manner above defined until steady state conditions are attained; and thereupon recycling a portion of the filtered reactor gaseous effluent substantially free of condensible gases to the reactor in lieu of the hydrocarbon fuel utilized in attaining steady state conditions, said effluent being introduced at a rate adapted to provide a combustion temperature of about that associated with the burning of the initially introduced hydrocarbon fuel while continuing to introduce a 25-75% stoichiometrical excess of the oxidant gas for burning said filtered gaseous effluent.

Claim 2

A method of operating an elongated, generally cylindrical reactor having an upstream and downstream end for the production of carbon black by the furnace process wherein the combustible gases generated a pyrolytically dissociating a carbon black producing feedstock are cyclically utilized as the fuel for effecting the dissociation reaction, which comprises: introducing a hydrocarbon fuel together with a 25-75% stoichiometrical excess of oxidant gas containing at least 70 volumetric percent oxygen into the upstream end of said reactor and substantially completely burning the fuel to provide a turbulent mixture of combustion gases; injecting a normally liquid aromatic-rich hydrocarbon feedstock into said turbulent mixture of combustion gases and burning said feedstock to the extent provided by the presence of free oxygen in the combustion gases while essentially simultaneously effecting the pyrolytical dissociation of the unoxidized portion of the feedstock to generate a carbon black aerosol; quenching the pyrolysis reaction and discharging the aerosol from the downstream end of the reactor whence the carbon black is recovered by filtration; continuously maintaining the production of carbon black in the manner above defined until steady state conditions are attained; and thereupon recycling a portion of the filtered reactor gaseous effluent substantially free of condensible gases to the reactor in lieu of the hydrocarbon fuel utilized in attaining steady state conditions, said effluent being introduced at a rate adapted to provide a combustion temperature of about that associated with the burning of the initially introduced hydrocarbon fuel while continuing to introduce a 25-75% stoichiometrical excess of the oxidant gas for burning said filtered gaseous effluent.