Industry Overview
Carbon black is a finely divided carbonaceous pigment produced through the thermal decomposition or incomplete combustion of hydrocarbon gases and oils. Depending on the manufacturing process, it is commonly classified into five principal types: lamp black, channel (or impingement) black, thermal black, acetylene black, and furnace black. The specific manufacturing method determines the physical characteristics of the product, enabling manufacturers to produce grades suitable for a wide range of industrial applications.
The most significant commercial properties of carbon black are particle size and surface area. Particle sizes generally range from 100 to 5000 Å, while surface area varies from 6 to 1,100 m²/g. Carbon content typically ranges from 83% to 99%. Structurally, carbon black consists of clusters of rough spherical particles with a partially crystalline arrangement of hexagonal carbon layers. The tendency of these particles to aggregate results from both physical and chemical bonding effects, making precise control of processing conditions essential for achieving the desired product characteristics.
Carbon black is valued for its deep black coloration, reinforcing properties, and broad industrial utility. The material is available in different grades to satisfy varying performance requirements, with smaller particle sizes and higher surface areas generally producing greater blackness. Because carbon black is a lightweight, fluffy powder, its handling requires appropriate dust-control measures and worker protection against inhalation. In industrial production, carbon black is formed primarily through the thermal decomposition of hydrocarbons, including furnace, channel, thermal, lamp black, and acetylene processes.
Cost Estimation
| Particular | Value |
|---|---|
| Plant Capacity | 36 MT/Day |
| Land & Building (10,000 sq.mt.) | Rs. 5.05 Cr |
| Plant & Machinery | Rs. 12.00 Cr |
| Working Capital for 1 Month | Rs. 7.01 Cr |
| Total Capital Investment | Rs. 24.75 Cr |
| Rate of Return | 32% |
| Break Even Point | 51% |
Content Index
- INTRODUCTION
- CARBON BLACK FEEDSTOCK
- PRODUCTION
- END USE
- MARKETING ARRANGEMENT
- TECHNICAL SPECIFICATION OF CARBON BLACK FEEDSTOCK
- AVAILABILITY OF RAW MATERIAL
- B I S SPECIFICATIONS
- FAST EXTRUSION FURNACE (FEF) CARBON BLACK
- 1. SCOPE:-
- 2. REQUIREMENTS:-
- 3. PACKING & MARKING:-
- 4. SAMPLING:-
- TABLE-1: REQUIREMENTS FOR FAST EXTRUSION FURNACE (FEP) CARBON BLACK
- IS: 7497-1974 SPECIFICATION FOR HIGH ABRASION FURNACE (HAF) CARBON BLACK
- 1. SCOPE:-
- 2. REQUIREMENTS:-
- TABLE -1: REQUIREMENTS FOR HAF CARBON BLACK
- 3 PACKING & MARKING:-
- 4 SAMPLING:-
- IS: 8134-1976 SPECIFICATION FOR INTERMEDIATE SUPER ABRASION FURNACE (ISAF) CARBON BLACK
- 1. SCOPE:-
- 2. GRADES:-
- 3. REQUIREMENTS:-
- 4. PACKING & MARKING:-
- 5. SAMPLING:-
- TABLE-1: REQUIREMENTS FOR INTERMEDIATE SUPER ABRASION FURNACE (ISAF:) CARBON BLACK
- IS: 40-1971 SPECIFICATION FOR CARBON BLACK FOR PAINTS
- 1. SCOPE:-
- 2. TERMINOLOGY:-
- 3. CLASSES & TYPES:-
- 4. REQUIREMENTS:-
- 5. BACKING & MARKING:-
- TABLE -1: REQUIREMENTS FOR CARBON BLACK FOR PAINTS
- 6. SAMPLING:-
- 7. TEST METHODS:-
- 8. CRITERIA FOR CONFORMITY:-
- IS: 7498-1974 METHODS OF SAMPLING AND TEST FOR CARBON BLACK
- 1. SCOPE:-
- 2. SAMPLING:-
- TABLE -1.: NUMBER OF BAG'S TO BE SAMPLED
- 3. QUALITY OF REAGENTS:-
- 4.1. APPARATUS:
- 5. IODINE ABSORPTION NUMBER:-
- 6. DIBUTYL PHTHALATE ABSORPTION (DBP):-
- 7. POUR DENSITY:-
- 8. SIEVE RESIDUE:-
- 9. LOSS ON HEATING:-
- 10. ASH CONTENT:-
- 11. ACETONE EXTRACT EXTRACT :-
- 12. STAINING TEST:-
- 14. SULPHUR CONTENT:-
- 15. PH VALUE:-
- USES AND APPLICATIONS
- APPLICATIONS OF MAJOR RUBBER GRADE CARBON BLACKS
- EFFECTS OF CARBON BLACK COLLOIDAL CHARACTERISTICS ON RUBBER PROCESSING & PHYSICAL PROPERTIES
- TYPES OF CARBON BLACKS
- STRUCTURE:-
- PRINTING INIKS:
- PAINT, LACQUERS, ENAMELS & INDUSTRIAL FINISHES:-
- PLASTICS:-
- PAPER:-
- OTHER APPLICATIONS:-
- TYPES OF CARBON BLACKS
- PROPERTIES OF CARBON BLACK
- SIEVE RESIDUE:
- PARTICLE SIZE:
- FIGURE: CARBON BLACK PARTICLE SIZE COMPARISON
- STRUCTURE:
- FIGURE: CARBON BLACK STRUCTURE
- SURFACE AREA:
- SURFACE CHEMISTRY:
- POROSITY:
- AGGREGATE SIZE:
- AGGREGATE SHAPE:
- MARKET OVERVIEW OF CARBON BLACK
- CARBON BLACK MARKET TRENDS
- INCREASING APPLICATION OF TIRES AND INDUSTRIAL RUBBER PRODUCTS
- CHINA TO DOMINATE THE MARKET IN THE ASIA-PACIFIC REGION
- CARBON BLACK MARKET LEADERS
- PRODUCTION OF CARBON BLACK
- EXPORT OF CARBON BLACK
- CONSUMPTION OF CARBON BLACK
- IMPORT OF CARBON BLACK
- MANUFACTURING PROCESS OF CARBON BLACK
- MANUFACTURING PROCESS HAS THE FOLLOWING SECTION:-
- MANUFACTURING PROCESS IN DETAILS
- CLASSIFICATION OF CARBON BLACK MANUFACTURING PROCESSES:
- TABLE: KINDS OF CARBON BLACK MANUFACTURING PROCESSES
- FURNACE BLACK METHOD:
- FIGURE: SCHEMATIC DIAGRAM OF THE INDIVIDUAL PROCESS STEPS IN A CARBON BLACK PRODUCTION UNIT
- FIGURE: INTERNAL DIAGRAM FOR THE FURNACE BLACK PROCESS
- LAMPBLACK PROCESS:
- FIGURE: LAMPBLACK PROCESS
- CHANNEL BLACK PROCESS:
- FIGURE: CHANNEL BLACK PROCESS OR GAS BLACK PROCESS
- THERMAL BLACK PROCESS:
- FIGURE: THERMAL BLACK PROCESS
- ACETYLENE BLACK PROCESS:
- FORMATION MECHANISM:-
- A MODEL REACTION MECHANISM OF CARBON FORMATION INVOLVES SEQUENTIALLY:-
- HEALTH AND SAFETY ASPECTS
- BASIC PROCESS OF CARBON BLACK
- FURNACE BLACK PROCESS EQUIPMENT:-
- TABLE: TIME- TEMP. CONDITION IN CARBON BLACK REACTORS
- REACTORS:
- POST RECTOR PROCESSING:
- (II) THERMAL BLACK
- FLOW DIAGRAM FOR CARBON BLACK MANUFACTURER
- III. CHANNEL BLACK:-
- FROM NATURAL GAS (CHANNEL PROCESS)
- PROCESS:-
- IV. ACETYLENE BLACK:-
- ADDRESSES OF PLANT & MACHINERY SUPPLIERS
- ADDRESSES OF PLANT & MACHINERY SUPPLIERS (IMPORTED)
- ADDRESSES OF RAW MATERIALS SUPPLIERS
Appendix
- 01. PLANT ECONOMICS
- 02. LAND & BUILDING
- 03. PLANT AND MACHINERY
- 04. OTHER FIXED ASSESTS
- 05. FIXED CAPITAL
- 06. RAW MATERIAL
- 07. SALARY AND WAGES
- 08. UTILITIES AND OVERHEADS
- 09. TOTAL WORKING CAPITAL
- 10. TOTAL CAPITAL INVESTMENT
- 11. COST OF PRODUCTION
- 12. TURN OVER/ANNUM
- 13. BREAK EVEN POINT
- 14. RESOURCES FOR FINANCE
- 15. INSTALMENT PAYABLE IN 5 YEARS
- 16. DEPRECIATION CHART FOR 5 YEARS
- 17. PROFIT ANALYSIS FOR 5 YEARS
- 18. PROJECTED BALANCE SHEET FOR (5 YEARS)
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