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Energy Recovery in the Carbon Black Industry
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Energy Recovery in the Carbon Black
Industry by Combustion Air Preheating
Carbon Black
Now is the right time to invest in
high temperatures air preheaters!
0
20
40
60
80
100
120
1997
1998
1999
2000
2001
2002
2003
2004
2005
2006
2007
(Oct
)20
08 (O
ct)
Crude oil price development 1997 – 2006 (USD / barrel)
650oC
BAGHOUSEFILTER
CARBON BLACK
COLD AIR
PREHEATED AIR 800°C
FUEL; OIL OR GAS
FEED OIL
EVAPCHAMBER
QUENCH WATER
AIR PREHEATER
Quench
Zone
Reaction
Zone
Combustion
Chamber
950oC
1300oC
260oC
Carbon Black Process
Carbon Black
EDS: Ekstrom Double Shell
Air Preheaters
Higher Air Preheating Temperatures
Higher air preheating temperature gives:
- Energy cost savings
- Higher carbon black production rate
A very profitable investment, with short pay-back time.
Carbon Black
Effects of Air Preheating
0
5
10
15
20
25
30
650 700 750 800 850
Perc
ent
Change (
%)
Air preheat Temperature (oC)
Fuel Saving
Carbon BlackProduction Rate
Feed Oil Rate
Carbon Black
Carbon Black
Annual cost savings at various air preheat temperaturesand oil prices, Average size Air Preheater
0
200
400
600
800
1000
1200
1400
1600
1800
650 °C 800 °C 900 °C
Air Preheat Temperature
kUSD/year
60 USD/barr
el
40 USD/bar
rel
100 USD/barr
el
Pay Back time for 650°C and 800°C Air Preheating
Pay B
ack T
ime (
years
)
Air preheat Temperature (oC)
60 USD/b
25 USD/b
Carbon Black
0
0.5
1
1.5
2
2.5
3
650 800
100 USD/b
Higher Air Preheating TemperaturesHigher Air Preheating Temperatures
Savings and improvements:
- 40% fuel cost saving
- 21% higher carbon black production rate
- 16% higher feed stock flow rate
- 3% higher carbon black yield- less CO2 emissions!
Investment:
One year pay-back time
Carbon Black
Design
- Fire Tubes 253MA, 88.9 mm
- Ferrules GRX (FeCrAl)
- DBTS Double bottom tube sheet with external cooling
- Bellows Each fire tube has top bellows with optimized convolutions, double ply
Carbon Black
Single Shell Design – The Standard Solution
CB gas in
Quench temp.
Air in
Air out
CB gas out
Cooling
air out
Cooling
air in
CB gas in
Quench temp.
Air in
Air out
CB gas out
Cooling
air out
Cooling
air in
Carbon Black
Double Shell Design – The Non Fouling Solution
CB gas in
Quench temp.
Air in Air out
CB gas out
Cooling
air inCooling
air in
CB gas in
Quench temp.
Air in Air out
CB gas out
Cooling
air inCooling
air in
Carbon Black
References
- Present on the market since 15 years
- Delivered to all major carbon black actors
- All type of APH sizes and carbon black qualities
- Focused on the high temperatures
- Size vs air flow
50
60
70
80
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100
110
120
130
140
150
5000 10000 15000 20000 25000 30000
Number of fire tubes vs design air flow
Design air flow (Nm3/hr)
Num
ber
of fire
tubes (
pcs)
Carbon Black
Higher Air Preheating Temperatures
Carbon Black
External slide (ESP 900 Degree C)
Summary
- Incentive for air preheating has never been higher
- 800 °C air preheating has proven to be a very profitable investment
- Energy cost saving
- Higher carbon black production rate
- The pay off time of a 800 °C air preheater is now one year
- Proven design
- A new 900 °C solution ready
Carbon Black
Please visit us on:www.ekstrom-son.se
Please visit us on:www.ekstrom-son.se
