Introduction: What’s RCB?
The process of recycling makes recovered carbon black a better and more sustainable substitute for Virgin carbon black. rCB is extracted from a tyre charge that has been pyrolysed through the process of pyrolysis of the tyre. This type of char manufactured in the procedure is composed of carbon black and in addition to a mixture of many compounds that are inorganic in nature. Under the respective process of pyrolysis, the rubber tire is heated in lack of oxygen and the process, or the phenomena is called thermal decomposition. As a result of thermal decomposition, the rubber material breakdown into its constituents in the form of gas, char and oil etc. The bye-products so obtained are sold in the market resulting in an efficient stream of revenue collection.
Virgin carbon black when compared to recovered carbon black
The former carbon content in traditional virgin carbon products is hiked up 100% of carbon and the reason behind is its source which is taken to be high fossil fuels and petroleum products such as coal etc. Comparatively the latter carbon black form old is an acquaintance from the tyres that were expected to end life within a short span of time and hence contains 15 to 20% of the inactive products like Ash and 80 to 85% of the carbon content. The basic points of difference between the two can be highlighted as under.
- Properties in relation to jetness and reinforcement
Industries like the polymer industry who is the importance of virgin carbon black due to its jet-black deep effect that comes from the largest area of the surface of small and tiny constituent particles. In the process of manufacture, the recovered carbon black has been obtained from milling phenomena of the particles to small-sized and uniform tiny black particles which offers a comparatively larger area for obesity and acquiring deep justness of shade.
The accurate jet black shade makes it perfect for being used for the purpose of coatings over plastic and rubber material. The basic reason for the difference between the former and the latter version of carbon black is basically the content of Ash that find its way towards the slightest decrease in the effect of black.
- Polycyclic hydrocarbons level
PAH normally present in virgin carbon black happy known to bring disasters to the health of mankind as well as to the nature and environment respective disastrous PAH levels have been found in different ready-to-consume products the same has been restricted as per the rules of the EU. Due to health concerns and other natural issues minimising the polycyclic aromatic hydrocarbon level in nature has become a priority and Benzo Alpha pyrene is taken to be a benchmark of the respective concentration. In the process of pyrolysis through the Waverly carbon, the carbon content is minimised making the recovered carbon black safe and heightening the sustainability of the same in comparison to the virgin carbon black.
- Comparative Formulation with traditional carbon black
The former carbon black is Subway subject to production in the form of powder or pellet. This powder form of carbon black is partially free-flowing and is utilised in the process of pigmentation. Because handling the same is tough and unsafe but for the safety of health and the environment, this has to be managed anyhow. Comparatively the recovered carbon black is safe and easy to ship even in bulk quantities. The ease of handling storage and less dusting make the required carbon black a better option as compared to the former one.
- Mechanism involved
The mechanism for obtaining recovered carbon black includes the procedures known as pyrolysis, devolatilization, pelleting and at times smiling etc. Please make it a perfect substitute and a sustainable product for being utilised. Moreover, the extraction of the same from end-life tyres makes the same a preferred choice comparatively.
Moreover, the recovered carbon black can be efficiently used by the tyre manufacturers just after obtaining grand news from the process of production. The sustainability of carbon black and its versatile applications make it an efficient and sustainable alternative to Virgin carbon black.
Integrated processes of production
The basic process of recycling the same in the companies depends on the alignment of systems and machinery with respect to the efficient working process line. Due to the effective alignment of various machine release, the production houses become the one-stop producers and the customers can contact the production houses for the product.
The finished rCB
With expert assistance, this can be produced with precise properties that the tyre produce or manufacturers of car tyres search for. From the desired dust-free product to the best quality granules the credit for the manufacture of the best quality recovered carbon black goes to the process of finishing the same. For the preparation of the same, the shredded and used tires of vehicles in addition to the Steel content are reduced to the maximum before the process of pyrolysis. The bye products in the form of oil and gas that are obtained through the procedure are utilised by different dealers and the residue left behind forms the base for the respective process of finishing.
Secondly, this material obtained after paralysis goes for transformation into the best quality granules of recovered carbon black. The three main steps included for the grinding of the same are fine grinding into the powder form followed by agglomeration which is then followed up by drying of the product.
The process of grinding includes the transformation of the product into the final material ranging from 5 microns to 15 microns. Moreover, the course tires for their production use 20-40 microns of rCB.
Handling and agglomeration
These are the two important processes under which the recovered carbon black is dosed well in addition to the perfect amount of binder. The moist granules are collected at the base of the flexomix machine. The flexibility of the chamber wall in this machine is massaged continuously for prevention of sticking of product. At times the companies may even use a pin mixer to agglomerate the same.
Then the final product is dried for obtaining the perfect granules of recovered carbon black. The direct positioning of the mixture over the perforated plate with the hot dry hair blowing through the holes assists in the process of drawing and finalizing the product packaging after the assured check.
All this procedure of manufacture makes recovered carbon black expensive and a complicated product. The respective procedure of pyrolysis requires efficient and skilled training in addition to a rich capital for establishing the production plant.
The wide range of applications of this recovered carbon black in place of virgin carbon black adds to the utility of the same in various fields.