rCB, a unique material

18th January 2017

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What is Carbon Black?

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Carbon Black

*Picture courtesy of Birla carbon

• A fine powder is produced via the partial combustion of heavy petroleum feedstock

• It is near 100% elemental carbon

• Identified by CAS # 1333-86-4

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Furnace Carbon Black Structure

Primary Particle Aggregate Agglomerate

~20 to 100nm Fused, chemically bonded

primary particles

Weak Van der Waals interactions between

aggregates

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N115N110

N134

N220

N234

N326

N330

N339

N375

N550

N660

N683

N772

N99040

50

60

70

80

90

100

110

120

130

140

0 20 40 60 80 100 120 140 160

Stru

ctu

re, (

OA

N v

alu

es

in c

c/1

00

g)

Surface Area (STSA values in m2g)

PASSENGER TREAD

TRUCK/ HIGH

PERFORMANCE TREAD

TYRE SIDEWALL/EXTRUSIONS

INNER LINER/ AV MOUNTS/ SEALING/

MOULDINGS

TYRE SKIM

COMPOUNDS

AV MOUNTS/ SEALING

CARCASS TREAD

Carbon Black Classification

Example = N330

Normal or Slow Cure

Indicates primary particle size

Arbitrarily assigned

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What is rCB?

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rCB Structure Development - Feedstock

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rCB Structure Development – Pyrolysis

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At this stage, the material is referred to as Char

ASTM D3053: Char is the unprocessed material obtained after a pyrolysis process of scrapped rubber goods. • May contain steel & fabric.

• Not-suitable for rubber applications.

• Low value.

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rCB Structure Development - Polishing

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ASTM D3053: A material recovered from scrapped rubber goods via pyrolysis, typically containing 10 to 20wt% of non-carbonaceous material. Has semi-reinforcing properties in the region of N600 to N700 series grades. • Free of steel & fabric. • Requires particle size reduction. • Requires pelletisation. • Many potential rubber and plastics

applications.

rCB Structure Development - Polishing

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rCB Properties

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2016 rCB Benchmarking Programme

• 25 rCB samples from 5 continents

• No char – but not all pelleted

• Mix of commercial and pilot scale processes

• Batch and continuous processes

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Colloidal Map

XT1004

N772

N660

N550

N326

0

10

20

30

40

50

60

70

80

90

100

0 10 20 30 40 50 60 70 80 90 100

Vo

id V

olu

me

50

MP

a (c

m3/1

00

g)

STSA (m2/g)

Furnace

rCB

• Confirms colloidal properties fall between N500→N300 series

• Narrow spread in structure (data generated bi HITEC).

• Broader spread in surface area.

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Cleanliness

• Spread in the cleanliness of rCB from different manufacturers

• Low volatile rCB has been associated with v. low PAH content

• High volatile content = poor reinforcement and strong odour!

44

65

8487

9398 98

51

43

68

74

9496

79 80

97

62

0

95100 98

2527

9593

98

84

74

98

67

39

N9

90

N7

72

N6

60

N5

50

N3

26

N3

30 #1 #2 #3 #4 #5 #6 #7 #8 #9

#10

#11

#12

#13

#14

#15

#16

#17

#18

#19

#20

#21

#22

#23

#24

#25

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Composition

• Differences in composition (averaged by region)

• Higher silica content in European rCB

0

10

20

30

40

50

60

70

80

90

100

N772 European NorthAmerica

SouthAmerica

SouthAfrica

Asia

We

igh

t %

Volatile

Carbon

Silica

ZnO

Other

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In-Rubber Dispersion

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N550 Dispersion Example

• Sections of ASTM D3192 compound.

• Uniform distribution of carbon black achieved.

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This is Achievable with rCB

• Sections of ASTM D3192 compound.

• Full post-rector processing necessary.

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Or Not!

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Physical Properties

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Carcass Grade Performance

0

20

40

60

80

100

120

Viscosity

Shore A

M300%

Tensile strength

Elongation to Break

Hysteresis, tan δ max

Refined rCB

N772

• Numerous studies performed to demonstrate the properties of rCB can match carcass grades.

• These studies have been conducted as benchmarking exercises – no formulation optimisation attain maximum rCB performance.

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Predicting Performance is Difficult!

N990

XT1004N772

N660

N550

N326

N330

N234

-8.0

-6.0

-4.0

-2.0

0.0

2.0

4.0

-20 -15 -10 -5 0 5 10

ΔM

30

0%

Δ Hardness

NXXX

rCB

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Predicting Performance is Difficult!

N990

XT1004N772

N660

N550

N326

N330

N234

-8.0

-6.0

-4.0

-2.0

0.0

2.0

4.0

-20 -15 -10 -5 0 5 10

ΔM

30

0%

Δ Hardness

NXXX

rCB

Those with poor dispersion or high volatile content removed.

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Dynamic Properties

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Strain Dependency

0

5

10

15

20

25

0.01 0.1 1 10

E', M

Pa

DSA, %

rCB Predicted

rCB Actual

N234

N330

N326

N550

N660

N772

N990

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Strain Dependency

N990

XT1004N772

N660

N550 #1

N550 #2

N550 #3

N326N330

N234

y = 0.1337x - 0.8479R² = 0.9726

0

2

4

6

8

10

12

14

16

0 20 40 60 80 100 120

∆E'

, MP

a

STSA, m2g

NXXX

rCB

• Confirms reduced surface activity (filler-filler interactions).

• Reduced hysteresis is a performance enhancer for some applications.

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Potential Applications

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Challenges

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Market Perception…

Volumes…

Oil Price…

Standardisation…

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Reasons to be optimistic

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Reduced CO2 Emissions…

Performance Enhancers…

Other Environmental Benefits…

Sustainable Source of Filler to Support Tyre Manufacturing Growth…

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Contact us:

Chris Norris PhD, MSc, BSc (Hons)

Chris.Norris@artis.uk.com

01225 896505

www.artis.uk.com

www.linkedin.com/company/artis_2

Questions?

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