Commodity Production Costs Report
Carbon Black Production
Carbon Black Operating Costs & Plant Construction Costs
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.
Key reference(s): ?
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.
Report in PDF Format
Download & Explore Anytime
Access in Various Devices
Print & Read Comfortably
Share With Co-workers
Up-to-date Report
Professional report based on Q3 2024 economic data, ensuring timely evaluations.
Multiple Use Cases
Ideal for investment screening, feasibility studies, cost estimates, and research planning.
Proven Methodology
Developed using a consistent methodology honed over a decade, ensuring reliable cost analyses.
Report Editions
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
Preview our Production Cost Reports
Could Not Find the Report You Need?
Obtain a Bespoke Report
Get a report targeting the process in which you are interested
See Offer Details
Understand Bespoke Reports and how you can easily order them
Check Editions & Pricing
Complete a brief form and see a quotation for your Bespoke Report
Other Related Production Cost Reports
Ethylene Glycol Production from Carbon Dioxide
This study presents the economics of Monoethylene Glycol (MEG) production from carbon dioxide (CO2) in the United States using an electrochemical process similar to Liquid Light process. Initially, CO2 is electrochemically reduced and acidified into oxalic acid. Then, oxalic acid is esterified with methanol producing dimethyl oxalate, which is hydrogenated forming MEG.
Details: 150 kta United States-based plant | Q3 2024 | 107 pages | Issue C | From $799 USD
Titanium Dioxide Production from Ilmenite (Chloride Process)
This study comprises a techno-economic analysis of an industrial process for Titanium Dioxide production from ilmenite in a facility located in the United States. In this process, ilmenite is converted by Benelite process into synthetic rutile, which is then chlorinated to titanium tetrachloride, and further oxidized to Titanium Dioxide.
Details: 180 kta United States-based plant | Q3 2024 | 107 pages | Issue C | From $1,199 USD
Ammonia Production from Fuel Oil
This report examines the costs related to Ammonia production from heavy fuel oil. The process under analysis integrates a heavy fuel oil partial oxidation process for synthesis gas production with a unit that produces ammonia from hydrogen and nitrogen. The economic analysis provided assumes a plant located in the United States.
Details: 800 kta United States-based plant | Q3 2024 | 107 pages | Issue E | From $1,199 USD
Maleic Anhydride from Butane (Fixed-Bed Reactor + Solvent-Based Recovery)
This feasibility study presents an analysis of Maleic Anhydride production from n-butane in the United States using a process similar to the one developed by Huntsman. In this process, maleic anhydride is produced by the partial oxidation reaction of n-butane with oxygen carried out in a fixed-bed reactor, using a vanadium–phosphorus oxide (VPO) catalyst supported on silica. The reactor effluent is directed to a solvent-based recovery system for Maleic Anhydride separation.
Details: 60 kta United States-based plant | Q3 2024 | 107 pages | Issue A | From $799 USD
+800 Reports Developed, Targeting +250 Commodities
Vast Report Library
858 independent and up-to-date reports examining embryonic and established production processes.
Free Sample Reports
Quickly understand the structure and depth of content of our professional reports.