公开(公告)号：US11149148B2

公开(公告)日：2021-10-19

申请号：US16097039

申请日：2017-04-28

Applicant: MONOLITH MATERIALS, INC.

Inventor： Roscoe W. Taylor ,  Alexander F. Hoermann ,  Peter L. Johnson ,  Robert J. Hanson ,  Aaron S. Hampton

IPC: C09C1/50 ,  C09C1/54 ,  B01J19/26 ,  C09C1/48 ,  B01J6/00

Abstract: Secondary heat may be added to a particle production process. The particles may be, for example, carbon particles. Among other things, the secondary heat addition may result in change in surface area of the carbon particle(s), change in structure of the carbon particle(s), reduced wall fouling, reduced energy consumption and/or increased throughput. Apparatus for performing the process is also described.

公开(公告)号：US10808097B2

公开(公告)日：2020-10-20

申请号：US15262539

申请日：2016-09-12

Applicant: MONOLITH MATERIALS, INC.

Inventor： Ned J. Hardman ,  Roscoe W. Taylor ,  Alexander F. Hoermann ,  Peter L. Johnson ,  Christopher J. -P. Cardinal ,  Robert J. Hanson

IPC: C09C1/52 ,  C08K3/04 ,  C09C1/48 ,  C08J5/00 ,  C01B32/15 ,  C09C1/50

Abstract: Carbon nanoparticles made in a one step process. A method of making carbon black nanoparticles is described, including adding a hydrocarbon to a heated gas to produce carbon nanoparticles that are less than 1 micron volume equivalent sphere and have an Lc greater than 3.0 nm. Elastomer composites containing such particles are also described.

公开(公告)号：US11926743B2

公开(公告)日：2024-03-12

申请号：US16563008

申请日：2019-09-06

Applicant: Monolith Materials, Inc.

Inventor： Peter L. Johnson ,  Alexander F. Hoermann

IPC: C09C1/50 ,  C01B3/24 ,  C01B32/05

CPC classification number: C09C1/50 ,  C01B3/24 ,  C01B32/05 ,  C01B2203/0272 ,  C01B2203/085 ,  C01B2203/1235 ,  C01P2006/12

Abstract: Systems and methods of making carbon particles with thermal transfer gas. A method of making carbon particles may comprise heating a thermal transfer gas by Joule heating and contacting the thermal transfer gas with a reactive hydrocarbon feedstock gas to generate the carbon particles and hydrogen gas. A method of making carbon particles may comprise heating a thermal transfer gas with the aid of Joule heating and mixing the thermal transfer gas with a hydrocarbon feedstock gas to generate the carbon particles.

公开(公告)号：US20230212401A1

公开(公告)日：2023-07-06

申请号：US17819075

申请日：2022-08-11

Applicant: Monolith Materials, Inc.

Inventor： Ned J. Hardman ,  Brian R. Allison ,  Anthony P. Spizuoco ,  Christopher E. Mesrobian ,  Alexander F. Hoermann ,  Dylan Laidlaw ,  Aaron S. Hampton

IPC: C09C1/48

CPC classification number: C09C1/48 ,  C01P2006/12 ,  C01P2006/90 ,  C01P2006/80

Abstract: Particles with suitable properties may be generated using systems and methods provided herein. The particles may include carbon particles.

公开(公告)号：US11591477B2

公开(公告)日：2023-02-28

申请号：US16445727

申请日：2019-06-19

Applicant: MONOLITH MATERIALS, INC.

Inventor： Peter L. Johnson ,  Alexander F. Hoermann ,  Roscoe W. Taylor ,  John J. Moss ,  Robert J. Hanson

IPC: C09C1/48 ,  B01J19/08 ,  H05H1/40 ,  H05H1/44

Abstract: A method and apparatus for making carbon black. A plasma gas is flowed into a plasma forming region containing at least one, magnetically isolated, plasma torch containing at least one electrode, and forming a plasma. Collecting the plasma formed in a cooled header and flowing the plasma through at least one reaction region to heat the reaction region, and injecting carbon black forming feedstock into the reaction region, resulting in the formation of at least one grade of carbon black. An apparatus for making carbon black is also described including a plasma forming section containing at least one, magnetically isolated plasma torch containing at least one electrode, in fluid flow communication with at least one carbon black forming reactor section, the plasma section and reactor section separated by a plasma formed collection header.

公开(公告)号：US11203692B2

公开(公告)日：2021-12-21

申请号：US16180635

申请日：2018-11-05

Applicant: MONOLITH MATERIALS, INC.

Inventor： Alexander F. Hoermann ,  Roscoe W. Taylor ,  Nils Severin Myklebust

IPC: B01J19/08 ,  C09C1/48

Abstract: A method and apparatus for making carbon black having increased surface area, reduced grit and/or reduced extract levels. A plasma gas is flowed into a plasma forming region to form a plasma. The plasma then flows through a throat region which is narrower than the plasma forming section, which is connected to a separate carbon black forming region. This causes the plasma to accelerate and become turbulent prior to the exit point in the throat region. The carbon black forming feedstock is injected into the turbulence created by the throat region at a point above, at or near the exit point, resulting in the formation of a carbon black in the separate carbon black forming region. The throat region and/or injector region can be cooled, e.g., water plasma gas cooled.

公开(公告)号：US20230279234A1

公开(公告)日：2023-09-07

申请号：US17938591

申请日：2022-10-06

Applicant: MONOLITH MATERIALS, INC.

Inventor： Alexander F. Hoermann ,  Roscoe W. Taylor ,  Christopher J.-P. Cardinal ,  Peter L. Johnson ,  Ned J. Hardman ,  Robert J. Hanson

IPC: C09C1/48 ,  H05H1/34 ,  H05H1/42 ,  C09C1/50 ,  B01J19/08

CPC classification number: C09C1/485 ,  H05H1/34 ,  H05H1/42 ,  C09C1/48 ,  C09C1/50 ,  B01J19/088 ,  H05H1/3431 ,  H05H1/3478 ,  B01J2219/0832 ,  B01J2219/0869 ,  B01J2219/0871 ,  B01J2219/0875 ,  B01J2219/0898

Abstract: A torch stinger apparatus may comprise one or more sets of plasma generating electrodes and at least one hydrocarbon injector contained within the electrodes. The electrodes may be concentric. The at least one hydrocarbon injector may be cooled. A method of making carbon particles using the apparatus is also described.

公开(公告)号：US20230136364A1

公开(公告)日：2023-05-04

申请号：US18046723

申请日：2022-10-14

Applicant: Monolith Materials, Inc

Inventor： Peter L. Johnson ,  Alexander F. Hoermann ,  Roscoe W. Taylor ,  John J. Moss ,  Robert J. Moss

IPC: C09C1/48 ,  B01J19/08 ,  H05H1/40 ,  H05H1/44

Abstract: A method and apparatus for making carbon black. A plasma gas is flowed into a plasma forming region containing at least one, magnetically isolated, plasma torch containing at least one electrode, and forming a plasma. Collecting the plasma formed in a cooled header and flowing the plasma through at least one reaction region to heat the reaction region, and injecting carbon black forming feedstock into the reaction region, resulting in the formation of at least one grade of carbon black. An apparatus for making carbon black is also described including a plasma forming section containing at least one, magnetically isolated plasma torch containing at least one electrode, in fluid flow communication with at least one carbon black forming reactor section, the plasma section and reactor section separated by a plasma formed collection header.

公开(公告)号：US20220339595A1

公开(公告)日：2022-10-27

申请号：US17565864

申请日：2021-12-30

Applicant: Monolith Materials, Inc.

Inventor： Roscoe W. Taylor ,  Alexander F. Hoermann

IPC: B01J19/08 ,  C09C1/48 ,  F27D1/00 ,  F27D9/00 ,  F27D17/00 ,  F27B3/24 ,  F28D21/00 ,  B01J19/00

Abstract: A method of cooling a liner in a plasma chamber. A recycle gas is contacted with or passed through the liner to cool the liner and pre-heat the recycle gas. The pre-heated gas is then recycled through the plasma chamber to become part of the plasma forming process. The method further comprises the liner is graphite, the recycle gas passes through at least one cooling channel present in the liner, at least one of the cooling channels are covered with at least one removable liner/channel cover, carbon deposits are formed from the presence of hydrocarbons in the recycle gas, at least one channel is formed in a spiral cooling channel pattern, at least one channel is formed in a substantially straight cooling channel pattern, and a plenum to aid in the production of an even distribution of cooling gas in the channels.

公开(公告)号：US11453784B2

公开(公告)日：2022-09-27

申请号：US16855276

申请日：2020-04-22

Applicant: Monolith Materials, Inc.

Inventor： Ned J. Hardman ,  Brian R. Allison ,  Anthony P. Spizuoco ,  Christopher E. Mesrobian ,  Alexander F. Hoermann ,  Dylan Laidlaw ,  Aaron S. Hampton

IPC: C09C1/00 ,  C09C1/48

Abstract: The present disclosure provides, for example, systems and methods for generating carbon particles. Carbon particles may have a total content of polycyclic aromatic hydrocarbons of less than or equal to about 0.5 parts per million, a content of benzo[a]pyrene of less than or equal to about 5 parts per billion, and a water spreading pressure that is less than about 5 mJ/m2. A carbon particle among the carbon particles may comprise less than about 0.3% sulfur by weight or less than or equal to about 0.03% ash by weight.