CARBON BLACK COMBUSTABLE GAS SEPARATION

Abstract

A method of separating combustible gasses from the pores of carbon black. A method of making carbon black in a reactor is described that results in a high concentration of combustible gasses contained in the pores of the carbon black produced. The combustible gasses contained in the pores are replaced with inert gas to render the carbon black safer to process in downstream equipment.

Claims

1.-17. (canceled)

18. A method of making carbon black, comprising: (a) generating the carbon black in a reactor, wherein the carbon black comprises pores comprising flammable gasses in an amount greater than 30% by volume on a dry gas basis; and (b) directing an inert gas to the carbon black to replace at least a portion of the flammable gasses contained in the pores with the inert gas to yield a reduced concentration of the flammable gasses in the pores of the carbon black, wherein the reduced concentration of the flammable gasses is below a flammability limit of the combustible gasses.

19. The method of claim 18, wherein the carbon black is generated in a plasma process.

20. The method of claim 18, further comprising discharging the carbon black into an upward flowing stream of the inert gas to cause the portion of the flammable gasses contained in the pores to diffuse into the inert gas, while the inert gas diffuses into the pores.

21. The method of claim 18, wherein the at least the portion of flammable gasses are replaced by changes in absolute pressure.

22. The method of claim 18, wherein the at least the portion of the flammable gasses are replaced by the inert gas by changes in temperature.

23. The method of claim 18, wherein the inert gas is nitrogen.

24. The method of claim 18, wherein the inert gas is a noble gas.

25. The method of claim 18, wherein the inert gas is steam.

26. The method of claim 18, wherein the inert gas is carbon dioxide.

27. The method of claim 18, further comprising mixing the at least the portion of the flammable gasses with the inert gas to form a mixture, wherein the mixture is suitable for use as a fuel.

28. The method of claim 27, further comprising concentrating the at least the portion of the flammable gasses for use as another fuel.

29. The method of claim 28, wherein the concentration of the at least the portion of the flammable gasses is obtained by pressure swing adsorption or absorption, vacuum pressure swing adsorption or absorption, temperature swing adsorption or absorption, condensation of the inert gas, molecular sieves or other membranes, or scrubbing.

30. The method of claim 28, wherein the concentration of the at least the portion of the combustible gasses is obtained by flowing the flammable gasses through the carbon black to remove the flammable gasses.

31. The method of claim 28, wherein concentration of the at least the portion of the combustible gasses is obtained by utilization of a fluidized bed.

32. The method of claim 27, further comprising separating the mixture into components for use as chemical feedstocks.

33. The method of claim 32, wherein the separation of the at least the portion of the flammable gasses is obtained by pressure swing adsorption or absorption, vacuum pressure swing adsorption or absorption, temperature swing adsorption or absorption, condensation of the inert gas, molecular sieves or other membranes, or scrubbing.

34. The method of claim 32, wherein the separation of the at least the portion of the flammable gasses is obtained by flowing the gasses through the carbon black to remove the flammable gasses.

35. The method of claim 32, wherein the separation of the at least the portion of the flammable gasses is obtained by utilization of a fluidized bed.

36. The method of claim 18, wherein the reduced concentration of the flammable gasses is less than 5.5% hydrogen by volume.

37. The method of claim 18, wherein the reduced concentration of the flammable gasses is less than 1% hydrogen by volume.

Description

EXAMPLE

[0022] A plasma black as made is filtered into a vessel where most of the effluent gasses have passed through the filter. The pores of the plasma black are filled with combustible gasses in such a quantity that >80% of the volume of the black is filled with hydrogen. A 200 kg (kilogram) process sample of black, despite the carbon having a density of ˜1800 kg/m.sup.3 (meters.sup.3), will have a pour density of approximately 50-200 kg/m.sup.3 in the vessel, and so there is up to approximately 3.9 m.sup.3 of combustible gasses in the pores of the black that occupies up to 4 m.sup.3 of vessel volume. These gasses are subjected to a nitrogen pressure swing such that the nitrogen is purged into the system at a pressure of 5 bar (or higher). The gasses are then released and the gases contained in the pores would now constitute 80% nitrogen and 20% hydrogen. Repeating this process then results in a similar 80% reduction in the hydrogen concentration in the pores, so that after multiple cycles the hydrogen has been substantially replaced by nitrogen rendering the pore gasses inert. For this example, 3 degas iterations were run at a pressure of 5 bar to reduce the amount of combustible gasses remaining in the pores to less than 1% hydrogen by volume. The flammability limit for hydrogen in nitrogen is 5.5%.

[0023] Thus, the scope of the invention shall include all modifications and variations that may fall within the scope of the attached claims. Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims.