Carbon Black - An Outlook for Opportunities
Introduction to Carbon Black
Carbon black results from partial or incomplete combustion or decomposition of aromatic oils, liquids, and gaseous hydrocarbons. Due to various preparation methods, carbon black is also widely recognized as furnace black, lamp black, acetylene black, channel black, and thermal black.
Carbon black is a well-recognized commodity product in European markets. It is commonly available in various forms, such as powder, granules, and pellets. It is identified by EINECS 215-609-9 and CAS no 1333-86-4. It comprises pure elemental carbon and minute contaminants from the manufacturing process.
Carbon black's main applications are in end-products that require characteristics such as color and tint properties, and reinforcement performance such as modulus and tensile strength, viscosity, die swell, and fatigue resistance. It also provides high resilience and abrasion resistance for use in rubber products.
The Value Chain
The key raw material for the manufacture of carbon black is carbon black
feedstock (CBFS) or carbon black oil (CBO). This is procured either from oil refineries or from coal tar distillers. Ships and bulk containers can also import the feedstock into European markets from the Middle East. Dow Chemical Company’s Aromatic Division provides CBFS to European markets, apart from a few other recognized suppliers.
Manufacturing and production of carbon black has been dominated by a few
multinational companies such as Degussa AG, Cabot Corp, and Columbian Chemicals Company, which hold 50 to 60 percent of the global volumes. The rest of the global market is highly fragmented and dictated by regional competitiveness. In Europe, Degussa AG is considered the market leader in carbon black manufacturing. The distribution of these products comprises manufacturers dealing directly with end-users and also distributing to remote locations.
The primary end-application for carbon black is the rubber market sector. Within this market, the production of automobile tires accounts for a significant proportion of total usage. Other non-tire applications include its use in rubber products such as conveyor belts, flaps, hoses, and gaskets. Plastic industries also widely use carbon blacks for their masterbatch applications in fibers, moldings, conductive packaging, semi-conductive cable compounds, and films. As pigment black, they find use in a wide range of applications such as in printing, carbon paper, inks, paints & coatings, enamels, paper, printer cartridges and toner, leather finishes, dry-cell batteries, electrodes and carbon brushes, and tapes.
Hurdles in the Market
The major hurdle for carbon black manufacturers is the emission of CO2 gas. Under the Kyoto Protocol, most countries have agreed to reduce and minimize their greenhouse emissions. In addition to CO2, other gases, including nitrous oxide, hydrofluorocarbons, perfluorocarbons, and sulfur hexafluoride, have been prime targets. The European Community has commitments to achieve reductions in its emissions levels by 2012 at 92 percent of the base year 1990. This is a considerable challenge to manufacturers,
who need to explore alternative solutions to CO2 usage.
Globally, there have been concerns over carbon black and its possible harmful effects on humans, though the evidence collected has been inconclusive. The International Agency for Research on Cancer (IARC) has labeled it a possible human carcinogen (Group 2 B).
Material handling and transport of products such as carbon black present a significant risk of soiling. As these products are available in various forms, it's possible to transport them in closed systems. Due to their flow properties, the most preferred mode of shipping is flexible intermediate bulk containers rather than rigid containers or silos.
Growth Opportunities
Carbon black volume growth is directly related to growth in rubber end-product markets. The volatility of tire production and mechanical rubber products is expected to impact carbon black manufacturers somewhat. Tyre production, in turn, depends on the growth of the automotive industry, which is witnessing stable growth of around 3 percent. Retreading in this market sector is emerging as both a boon and a bane. Tyre production will likely reduce with more retreading, while carbon black will be required in both markets. Inks, printing, and plastics are also significant markets for high-carbon
black usage. With technology advancements, new end-application use is likely to be developed in addition to existing end-use.
Conclusion
Growth in global automotive and plastic markets is likely to result in increased carbon black production to meet tyre demands. Simultaneously, carbon black manufacturers are continuously exploring technologies that minimize by-products while utilizing
them for beneficial use. Power regeneration using tail-gas and green house farming are a few examples that are already in place. End-product manufacturers, especially tyre manufacturers, also assume accountability for recycling their products and work closely with recyclers and government bodies to ensure efficient usage and a healthy environment.
By Mahesh S Kumar
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