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Energy Recovery in the Carbon Black Industry by Combustion Air Preheating

Now is the right time to invest in high temperatures air preheaters!


120 100 80 60 40 20 0
19 97 19 98 19 99 20 00 20 01 20 02 20 03 20 04 20 05 2 20 00 07 6 ( 20 Oc 08 t) (O ct )

Crude oil price development 1997 2006 (USD / barrel)

Carbon Black

Carbon Black Process


AIR PREHEATER

COLD AIR

650oC

260oC

PREHEATED AIR 800C


950oC

BAG HOUSE FILTER EVAP CHAMBER

QUENCH WATER FEED OIL


1300oC

FUEL; OIL OR GAS


Combustion Chamber Reaction Zone Quench Zone

CARBON BLACK

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

30 25
Percent Change (%) Fuel Saving

20 15 10 5 0 650

Carbon Black Production Rate Feed Oil Rate

700

750
Air preheat Temperature (oC)

800

850

Carbon Black

Annual cost savings at various air preheat temperatures and oil prices, Average size Air Preheater

1800 1600 1400 1200 1000 800 600 400 200 0

el D/barr 100 US

kUSD/year

/barrel 60 USD

el D/barr 40 US

650 C

800 C
Air Preheat Temperature

900 C

Carbon Black

Pay Back time for 650C and 800C Air Preheating

3
Pay Back Time (years) 25 USD/b

2.5 2 1.5 1 0.5


100 USD/b 60 USD/b

0 650 800
Air preheat Temperature (oC)

Carbon Black

Higher 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 out

Air in

Air out

Cooling air out CB gas in Quench temp.

Cooling air in

Carbon Black

Double Shell Design The Non Fouling Solution


CB gas out

Air in

Air out

Cooling air in CB gas in Quench temp.

Cooling 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
150 140 130

Number of fire tubes vs design air flow

Number of fire tubes (pcs)

120 110 100 90 80 70 60 50 5000

10000

15000

20000

25000

30000

Design air flow (Nm3/hr) Carbon Black

Higher Air Preheating Temperatures

External slide (ESP 900 Degree C)

Carbon Black

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