Aciniform carbon similar to carbon black is removed from the natural gas in the CarbonSaver
process. The dominant source of furnace carbon black is from oil. It is an expensive and energy-intensive process, involving the partial combustion of oil. As a result, carbon black plants are large emitters of CO2 and other pollutants. The carbon black industry consumes over 300,000 barrels of low-grade oil per day and generating 2.5 to 5 tonnes of CO2 for every tonne of carbon black produced. The CarbonSaver
technology produces carbon without generating any CO2. For the carbon black industry, this technology holds promise as an economical and a GHG-free method of carbon production. CarbonSaver
technology may be used to develop carbon products that are not derived from oil and produced without direct emission of CO2.
Initial evaluation of carbon produced by CarbonSaver
by AHI and Columbian Chemicals has demonstrated the potential of a value-added carbon, justifying capture and use in downstream products.
As part of the iron casting process, carbon is added to the molten mix, as shown in this foundry crucible.
The powders generally consist of highly branched aggregates resembling traditional carbon black. Beyond their use as a supplement/replacement for furnace carbon blacks, the near-term application for these carbons is as a metallurgical additive for raising carbon to correct levels in the manufacture of cast ductile and gray irons where the high purity of AHI's carbons creates value.
