Carbon nanoparticles made in a one step process. A method of making carbon black nanoparticles is described, including adding a hydrocarbon to a heated gas to produce carbon nanoparticles that are less than 1 micron volume equivalent sphere and have an Lc greater than 3.0 nm. Elastomer composites containing such particles are also described.

Core particles produced in situ or introduced as preformed core particles are coated with a layer of carbon. Non-carbon as well as some carbon-based core materials can be utilized. The resulting carbon coated particles can find applications in rubber products, for instance as reinforcement for tire components.

A method and apparatus for making carbon black. A plasma gas is flowed into a plasma forming region containing at least one, magnetically isolated, plasma torch containing at least one electrode, and forming a plasma. Collecting the plasma formed in a cooled header and flowing the plasma through at least one reaction region to heat the reaction region, and injecting carbon black forming feedstock into the reaction region, resulting in the formation of at least one grade of carbon black. An apparatus for making carbon black is also described including a plasma forming section containing at least one, magnetically isolated plasma torch containing at least one electrode, in fluid flow communication with at least one carbon black forming reactor section, the plasma section and reactor section separated by a plasma formed collection header.

A method of cooling a liner in a plasma chamber. A recycle gas is contacted with or passed through the liner to cool the liner and pre-heat the recycle gas. The pre-heated gas is then recycled through the plasma chamber to become part of the plasma forming process. The method further comprises the liner is graphite, the recycle gas passes through at least one cooling channel present in the liner, at least one of the cooling channels are covered with at least one removable liner/channel cover, carbon deposits are formed from the presence of hydrocarbons in the recycle gas, at least one channel is formed in a spiral cooling channel pattern, at least one channel is formed in a substantially straight cooling channel pattern, and a plenum to aid in the production of an even distribution of cooling gas in the channels.

Core particles produced in situ or introduced as preformed core particles are coated with a layer of carbon. Non-carbon as well as some carbon-based core materials can be utilized. The resulting carbon coated particles can find applications in rubber products, for instance as reinforcement for tire components.

A high temperature heat integration method of making carbon black. A method of making carbon black is described, including reacting a carbon black forming feedstock with hydrogen gas in a plasma reactor to produce effluent gas containing carbon black and unused hydrogen, cooling the effluent gas for further processing, and recycling the unused hydrogen back into the carbon black forming process, where the unused hydrogen gas is pre-heated in a heat exchanger to a temperature up to the reaction temperature in the reactor before being recycled into the carbon black forming process. The heat exchanger for use in such process is also described.

A method and apparatus for making carbon black having increased surface area, reduced grit and/or reduced extract levels. A plasma gas is flowed into a plasma forming region to form a plasma. The plasma then flows through a throat region which is narrower than the plasma forming section, which is connected to a separate carbon black forming region. This causes the plasma to accelerate and become turbulent prior to the exit point in the throat region. The carbon black forming feedstock is injected into the turbulence created by the throat region at a point above, at or near the exit point, resulting in the formation of a carbon black in the separate carbon black forming region. The throat region and/or injector region can be cooled, e.g., water plasma gas cooled.

Apparatus and process for the continuous production of carbon black or carbon containing compounds. The process is performed by converting a carbon containing feedstock, including generating a plasma gas with electrical energy, accelerating the plasma gas through a nozzle, whose diameter is narrowing in the direction of the plasma gas, guiding the plasma gas into a reaction area where feedstock is injected under conditions generated by aerodynamic and electromagnetic forces, including intense rapid mixing between the plasma gas and feedstock occurs. There is no significant recirculation of feedstock into the plasma chamber, and the reaction zone does not immediately come into contact with any contact surfaces. The products of reaction are cooled, and the carbon black or carbon containing compounds are separated from the other reaction products.

A method and apparatus for making carbon black. A plasma gas is flowed into a plasma forming region containing at least one, magnetically isolated, plasma torch containing at least one electrode, and forming a plasma. Collecting the plasma formed in a cooled header and flowing the plasma through at least one reaction region to heat the reaction region, and injecting carbon black forming feedstock into the reaction region, resulting in the formation of at least one grade of carbon black. An apparatus for making carbon black is also described including a plasma forming section containing at least one, magnetically isolated plasma torch containing at least one electrode, in fluid flow communication with at least one carbon black forming reactor section, the plasma section and reactor section separated by a plasma formed collection header.

A method of operating a plasma torch in a chemical reactor comprising a plasma torch and a liquid circulation system is described. Tin the liquid circulating system comprises a conductive material solid at ambient temperature and liquid at a reaction temperature. The method first involves operating the plasma torch to decompose a feedstock gas, so that the decomposition products are output into the liquid circulating system. The plasma torch is then shut down, with the result that an electrode of the plasma torch is at least partially flooded by conductive material from the liquid circulating system. The conductive material cools to form a conductive plug. On reigniting the plasma torch to restart the chemical reactor, a conduction path is formed through the conductive plug to melt it.