Waverly Carbon make two Recovered Carbon Black products:
Recycled carbon black products can also work with the ink industry and other applications where a high concentration of carbon is required.
Waverly Emerald 210 and 220 are our two rCB grades in powder form, produced to a tied specification. Emerald 210 uses raw material feedstock that is from passenger tyres, whereas Emerald 220 is from a combination of passenger and truck tyre raw material feedstock blended in fixed proportions to ensure a consistent quality. The material is milled down to a fine particle size to aid consistency and dispersion when added to the plastic or rubber compound. Both grades can be packaged directly in either bulk bags or 20kg sacks. Their powder form aids dispersion in aqueous solution or compounds with very low viscosity. .
Emerald 215 and 225 are our two rCB grades in pellet form, produced to a tied specification. Similar to 210, Emerald 215 is from pure passenger tyre feedstock, and Emerald 220, like 225, is from a fixed blend of passenger and truck tyres. Once milled to a consistent size the milled powder is then treated with a secondary process where the refined rCB powder is processed through a pelletiser to produce uniform pellets, similar to virgin carbon black pellets. Pelleted material assists conveying systems (such as conveyors, belts, dosing units and pipes that help move material around a factory) for bulk handling and ensures better dispersibility in both plastic masterbatch and rubber compounding.
Waverly Emerald grades can be used as a replacement or partial replacement (with high percentage substitution) for grades like carbon black N550 or total replacements for the N600, N700 and N900 series.
Waverly rCBg and Waverly rCBp can be used as a replacement or partial replacement (with high percentage substitution) for grades like carbon black N550 or total replacements for the N600, N700 and N900 series.
Due to the morphology of rCB (from the original virgin carbon black grades used in tyres), high structure, high surface area and low reinforcing properties in line with the N500, N600 and N700 families, our rCB exhibits very good dynamic properties giving the customer, low hysteresis, lower storage modulus and low Tan delta compared to current carbon blacks used for similar applications.
For higher strength applications with a need for greater reinforcing properties we are currently working with our suppliers to develop a rCB with higher reinforcing capabilities through the pyrolysis process. Lower ash content within the raw material feedstock will increase the carbon black component within the rCB so will generally offer greater reinforcing properties.
Normal furnace carbon black has a graphitic surface which allows the increase in conductivity, which depends on the structure and surface area of the specific carbon black grade. Recovered carbon black has some inorganic material and saturated carbon on the surface, therefore, the electrical resistivity of rCB lies in between pure and oxidised furnace black. This allows the use of Recovered Carbon Black for specific electrical applications; where low conductivity is required and the band on the conductivity is narrow and stable regardless of the loading level of rCB in the compound.
Our R&D team has developed a cost-effective method for removing impurities from rCB. In late 2023 we will be installing our first ash removal line, capable of producing 180 tonnes per year. This material will contain less than 1% ash content, which will allow for its use as a full or partial substitute to the carbon black N300 and N500 series, such as the popular carbon black N550. This rCB achieves similar physical properties for the desired compound, whether for plastic or rubber, and will be a direct 1 for 1 replacement for N550 in many applications.
Following successful testing, Emerald Pure will be launched in 2023 and expand line capacity subject to demand. Emerald Pure will be available as a granulated product and as a powder in bulk bags.
Recovered Carbon Black has many attractive characteristics
With its environmentally friendly footprint and near zero emissions incurred during production, the environmental benefits of Recovered Carbon Black is stark in comparison with virgin carbon black production.
Waverly Carbon is working with sustainability consultants to conduct a certified life cycle assessment. Our focus is on delivery based on the following environmental statements:
If you would like to speak to us about our Recovered Carbon Black please contact us