Carbon Black Production
Carbon Black Production Costs Report | Issue A | Q4 2024
| Report Details |
| 150 kta United States-based plant | Q4 2024 | 107 pages |
This report presents a cost analysis of a 150 kta (kilo metric ton per annum) United States-based plant. You can add a customized cost analysis, assuming another location (country), when ordering a premium edition of this report.
Report Abstract
This study approaches the economics of Carbon Black production from fuel oil in the United States via a typical oil-furnace process. In the process examined, the oil feed is combusted in a reactor, producing Carbon Black and tailgas. After cooling, the carbon black is separated from the tailgas, processed into pellets and dried.
The report provides a comprehensive study of Carbon Black production and related Carbon Black production cost, covering three key aspects: a complete description of the Carbon Black production process examined; an in-depth analysis of the related Carbon Black plant capital cost (Capex); and an evaluation of the respective Carbon Black plant operating costs (Opex).
The Carbon Black production process description includes a block flow diagram (BFD), an overview of the industrial site installations, detailing both the process unit and the necessary infrastructure, process consumption figures and comprehensive process flow diagrams (PFD). The Carbon Black plant capital cost analysis breaks down the Capex by plant cost (i.e., ISBL, OSBL and Contingency); owner's cost; working capital; and costs incurred during industrial plant commissioning and start-up. The Carbon Black plant operating costs analysis covers operating expenses, including variable costs like raw materials and utilities, and fixed costs such as maintenance, labor, and depreciation.
Process Schematic
The process under analysis comprises two major sections: (1) Reaction and (2) Finishing.
Reaction. Natural gas is burned with excess air in the first zone of the furnace reactor. This burned stream is directed to the second reactor zone, where it is mixed with preheated oil feedstock. The heat generated by the combustion of natural gas and a small part of oil is responsible to achieve the desired temperature for the oil pyrolysis (about 1,500 °C), forming Carbon Black. The reaction mixture is then rapidly cooled by a quench with process water inside the reactor to avoid the formation of undesirable by-products. Subsequently, the output reactor's stream is further cooled in a quench tower.
Finishing. The cooled stream is filtered in a bag-filter, separating tail gas from Carbon Black. The filtered black passes through a cyclone separator. At this point, Carbon Black is a low-density powder and should be pelletized, by means of a wet pelletizer. After pelletization, it is dried in a rotary-dryer. Finally, the Carbon Black product is homogenized and packed. The tail gas is divided into two parts: the first is directed to the dryer to be burned as fuel for the equipment. The other part goes to an OSBL cogeneration unit, where it is burned to generate electricity.
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Production Process Information
Process Consumptions
Labor Requirements
Plant Capital Cost Summary
Operating Cost Summary
Production Costs Datasheet
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Production Process Information
Process Consumptions
Labor Requirements
Plant Capital Cost Summary
Operating Cost Summary
Production Costs Datasheet
Plant Capital Cost Details
Operating Cost Details
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Updated with Q4 2024 Data
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Production Process Information
Process Consumptions
Labor Requirements
Plant Capital Cost Summary
Operating Cost Summary
Production Costs Datasheet
Plant Capital Cost Details
Operating Cost Details
Plant Cost Breakdowns
Plant Capacity Assessment
Process Flow Diagrams
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Content Highlights
Plant Capital Cost Summary
Summary outlining the capital cost required for building the Carbon Black production plant examined
Plant Capital Cost Details
Detailing of fixed capital (ISBL, OSBL & Owner’s Cost), working capital and additional capital requirements
Plant Cost Breakdowns
Breakdown of Carbon Black process unit (ISBL) costs and infrastructure (OSBL) costs; plant cost breakdown per discipline
Operating Costs Summary
Summary presenting the operating variable costs and the total operating cost of the Carbon Black production plant studied
Operating Cost Details
Detailing of utilities costs, operating fixed costs and depreciation
Plant Capacity Assessment
Comparative analysis of capital investment and operating costs for different Carbon Black plant capacities
Production Process Information
Block Flow Diagram, descriptions of process unit (ISBL) and site infrastructure (OSBL)
Process Consumptions
Raw materials and utilities consumption figures, by-products credits, labor requirements
Process Diagrams
Process flow diagrams (PFD), equipment list and industrial site configuration
Other Carbon Black Production Cost Reports
Carbon Black Production
This study approaches the economics of Carbon Black production from fuel oil in the United States via a typical oil-furnace process. In the process examined, the oil feed is combusted in a reactor, producing Carbon Black and tailgas. After cooling, the carbon black is separated from the tailgas, processed into pellets and dried.
Details: 150 kta United States-based plant | Q4 2024 | 107 pages | Issue A From $999 USD
The cost analyses presented in this report target a 150 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.
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