Method of making a multi-phase aggregate using a multi-stage process
AssigneeCabot Corporation
InventorsKhaled Mahmud, Meng-Jiao Wang, Yakov Kutsovsky
Life of this patent
Estimating the term…
Abstract
A method of making an aggregate having a carbon phase and a silicon-containing species phase is described and includes introducing a carbon black-yielding feedstock and a silicon-containing compound feedstock into different stages of a multi-stage reactor. The reactor operates at a sufficient temperature to decompose the silicon-containing compound and to form a carbon black phase from the carbon black-yielding feedstock. At least one of the feedstocks may include a diluent, such as an alcohol, water, and aqueous based solution, and mixtures thereof.
Claims130
An aggregate comprising a carbon phase and a silicon-containing species phase, wherein said aggregate is characterized by at least one of the following characteristics:
- a) a difference between BET (N2) surface area and t-area of from about 2 to about 100 m2/g;
- b) a difference between BET (N2) surface area and t-area of from about 1 to about 50 m2/g after HF treatment;
- c) a ratio of from about 0.1 to about 10 based on 1) the difference in BET (N2) surface area between the aggregate after and before HF treatment to 2) weight percentages of silicon content in said aggregate without HF treatment;
- d) a weight average aggregate size measured by DCP after HF treatment is reduced by about 5% to about 40% compared to weight average aggregate size without HF treatment;
- e) a silica ash content in said aggregate of from about 0.05% to about 1% based on the weight of said aggregate after HF treatment and based on ash resulting from silicon-containing compound;
- and
- f) A BET surface area of silica ash in said aggregate of from about 200 m2/g to about 700 m2/g.
A method of making an aggregate comprising a carbon phase and a silicon-containing species phase, said method comprising:
- introducing a first feedstock into a first stage of a multi-stage reactor having at least two stages for introducing feedstocks;
- introducing at least a second feedstock into said reactor at a location downstream of said first stage;
- wherein at least one of the feedstocks comprises a carbon black-yielding feedstock and at least one of the feedstocks comprises a silicon-containing compound;
- and wherein said reactor has a sufficient temperature to decompose said silicon-containing compound and to form carbon black from the carbon black-yielding feedstock and wherein at least one of said first and second feedstocks includes a diluent.
An aggregate comprising a carbon phase and a silicon-containing species phase, wherein said aggregate is characterized by at least one of the following characteristics:
- a) a difference between BET (N2) surface area and t-area of from about 2 to about 100 m2/g;
- b) a difference between BET (N2) surface area and t-area of from about 1 to about 50 m2/g after HF treatment;
- c) a ratio of from about 0.1 to about 10 based on 1) the difference in BET (N2) surface area between the aggregate after and before HF treatment to 2) weight percentages of silicon content in said aggregate without HF treatment.
- d) a weight average aggregate size measured by DCP after HF treatment is reduced by about 5% to about 40% compared to weight average aggregate size without HF treatment;
- e) a silica ash content in said aggregate of from about 0.05% to about 1% based on the weight of said aggregate after HF treatment and based on ash resulting from silicon-containing compound;
- and
- f) A BET surface area of silica ash in said aggregate of from about 200 m2/g to about 700 m2/g, wherein the silicon-containing species phase is present primarily at the surface of the aggregate.
An aggregate comprising a carbon phase and a silicon-containing species phase, wherein said aggregate is characterized by at least one of the following characteristics:
- a) a difference between BET (N2) surface area and t-area of from about 2 to about 100 m2/g;
- b) a difference between BET (N2) surface area and t-area of from about 1 to about 50 m2/g after HF treatment;
- c) a ratio of from about 0.1 to about 10 based on 1) the difference in BET (N2) surface area between the aggregate after and before HF treatment to 2) weight percentages of silicon content in said aggregate without HF treatment.
- d) a weight average aggregate size measured by DCP after HF treatment is reduced by about 5% to about 40% compared to weight average aggregate size without HF treatment;
- e) a silica ash content in said aggregate of from about 0.05% to about 1% based on the weight of said aggregate after HF treatment and based on ash resulting from silicon-containing compound;
- and
- f) A BET surface area of silica ash in said aggregate of from about 200 m2/g to about 700 m2/g, wherein said aggregate has silanol groups located at the surface of the aggregate.
Dependencies are inferred from the claim text.