CleanCarbHy

Français

A clean process for carbon nanoparticles and hydrogen production from plasma hydrocarbon cracking.

• Project funded by the European Commission under the ‘Non Nuclear Energy JOULE III’ Programme
• Contract Number JOE-CT97-0057
• Start Date : 01.12.1997 / End Date : 30.11.2000

1 - INTRODUCTION AND OBJECTIVES

The current production process applied in carbon black manufacturing, the so-called Furnace Process based on the incomplete combustion of heavy hydrocarbons, is characterised by poor carbon yields (20 % to 30 %) and a high level of atmospheric emissions (CO₂, NO_x, sulphurous products, etc). The idea of this R&D project consists in replacing the incomplete combustion process by a hydrocarbon cracking process using an electric energy supply given by a plasma arc :

In addition to the set up of a new clean, raw material and energy saving process, there are two additional objectives:

• Production of hydrogen as a co-product.
• Production of new carbon nanostructures for new market applications, due to much higher temperatures than in the furnace process.

ARMINES and IMP-CNRS have been working since 1992 on the development of a new plasma technology for carbon nanoparticles and hydrogen production from hydrocarbon cracking. ERACHEM COMILOG S.A. (Formerly MMM) and TIMCAL, two European industrial companies specialised in the production of carbon black and graphite, respectively, joined their R&D efforts to support the development of this new clean electro-thermic continuous process for direct carbon nanoparticles and hydrogen production. The development of the electric power system was taken in charge by TETRONICS, a specialist manufacturer of plasma systems.

The term carbon black refers to a wide group of industrial carbon products, which amount to a worldwide production of about 7 million tons per year. Most of this production goes into the rubber industry (tires), carbon black being used as a filler material. Other applications include electric and electrochemical domains (cells, electronic components, conductive polymers), inks, paints, etc.

Product analysis of the synthesised plasma blacks is carried out at different levels. First, physico-chemical tests are performed:

• chemical composition, ash content, etc,
• crystalline structure,
• micro porous texture,
• particle size distribution.

Depending on the results, applicative tests may be carried out in the domains of battery cells, rubbers, and plastics.

2 – RESULTS

TEM image of plasma carbon black grade.

Replacement of incomplete combustion by an external energy supply (plasma arc) in the total absence of oxygen which leads to a totally clean process (zero emission). One process for the production of two valuable products: Carbon and hydrogen. Greater flexibility, in that the new process will accept any hydrocarbon feedstock. Plasma blacks show similar performance to existing blacks in dry-cells (Zn/C), thermoplastic compounds and rubber compounds. New operating conditions that allow very high temperatures with the possibility to obtain new carbon blacks. 100 % carbon recovery. No CO2, SO2, NOx… emission on the production site. No emission at all if the electricity is of non-fossil origin Optimised plasma facility for continuous operation.

3 – CONSORTIUM

• ERACHEM COMILOG S.A. (Formerly MMM S.A.) (BE) coordinator
• ARMINES Centre for Energy Studies / Ecole des Mines de Paris (FR)
• CNRS-IMP French National Centre for Scientific Research (FR)
• TIMCAL G+T (CH)
• TETRONICS Ltd (UK)

Equipment         Members         Projects         Publications

Plasma Conversion Processes