Decarbonisation options for the Dutch carbon black industry
Y. Abdallas Chikri and W. Wetzels
Location
TNO
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Abstract
Carbon black is a product widely used in industry to enhance the mechanical, electrical and optical properties of the materials where it is integrated as a filler. Most of the industrially produced carbon black is consumed by the tyre manufacturing industry and the remainder is used in rubber products and diverse applications such as plastics, paint and printing ink. In the Netherlands the only carbon black manufacturer is Cabot B.V., which has a production capacity of 80,000 tonnes carbon black/year. This plant manufactures different grades of carbon black through the use of furnace black reactors, the predominant method for carbon black production. Cabot B.V. is situated in the Botlek area in the Port of Rotterdam. From 2008 to 2018, the Botlek plant’s greenhouse gas emissions ranged from 195 to 247 kilotonnes CO2-eq. Carbon black is produced in a reactor using liquid hydrocarbons (feedstock), natural gas (fuel) and air (oxidant). The resulting product is a mixture of tail gas and suspended carbon black. Through filtration, the tail gas and fluffy carbon black are separated and made available for further processing. Direct greenhouse gas emissions result from the combustion of the tail gas in the plant. The energy consumption and the emission factor are approximately 44 GJ/tonne carbon black and 3.3 tonne CO2/tonne of carbon black, respectively. The main decarbonisation options for the industrial production of carbon black that have been identified are: • Electrification of the process through plasma technology, which has already been developed and scaled up. These technologies also produce hydrogen. The carbon black manufactured in the plasma reactor is further processed in order to deliver the final product (pelletized carbon black). For the drying process, steam from an electric boiler can be used. • Carbon capture is a mature technology that could be used to capture CO2 from the flue gas. In the future, services for CO2 transport and storage could be contracted in the Port of Rotterdam. The captured CO2 can also be delivered to greenhouses or used in nearby industries. • Bio-SNG (Substitute Natural Gas) obtained from biomass can substitute natural gas use in the reactor. Bio-SNG can be produced by upgrading biogas or synthetic gas to the same quality as natural gas. Possibly, biogas that has not been upgraded may be used as well. This may affect the quality of the product or the conditions in the reactor. Furthermore, the hydrocarbon feedstock (oil) could be substituted by bio-based feedstocks e.g. pyrolysis oil and/or bio-SNG. However, the former is at an experimental state and the latter has limited yields. Finally, carbon black could also be recycled from tyre waste through a pyrolysis process. The company Black Bear transforms used tyres into carbon black in a plant located in Nederweert.