Carbon black is a key component in technical rubber and pigment applications, and its quality depends heavily on precise thermal process control. SCHACK® technologies provide proven, energy-efficient solutions across all key stages of carbon black production – from quenching, air and oil preheating, and steam generation to product drying and tailgas treatment.
Our systems are designed to meet the high thermal demands of carbon black manufacturing, with a focus on energy recovery, process stability, and emission reduction. From Air Preheaters capable of handling over 30,000 Nm³/h, to Quench Boilers, Rotary Dryers, and Tailgas Boilers, each component is optimized for performance, reliability, and sustainability.
Built on decades of experience and advanced simulation methods, SCHACK® heat recovery systems support the industry’s need for maximum efficiency and low environmental impact – from feedstock preheating to waste heat utilization. Every unit is tailored to plant-specific needs while delivering long-term value through robust operation and reduced operating costs.
The SCHACK® Air Preheater is a key driver of process efficiency in carbon black plants. With preheating capabilities of up to 950 °C, it significantly boosts plant performance while meeting the highest standards of reliability and operational safety.
Higher air preheating temperatures directly reduce feedstock and fuel consumption. A 200 °C increase can lower feedstock use by up to 6%, while a 300 °C increase can cut fuel costs by up to 15%. At the same time, reaction throughput can rise by up to 50%, and quench water demand may drop by 20%, improving both yield and resource efficiency.
The SCHACK® Air Preheater is engineered to withstand the extreme conditions of carbon black production, including high process temperatures, corrosive gas compositions, and particle-laden flows. Designed on the “flue gas through the tubes” principle, it efficiently recovers heat from process gas to preheat reaction air — a key factor in yield quality and plant economics.
With a proven design legacy dating back to 1957, today’s SCHACK® Air Preheater achieves air preheating temperatures up to 950 °C, setting a global benchmark in carbon black technology. Its baffle-guided shell-side flow ensures uniform heat transfer and process stability.
By enhancing thermal efficiency, supporting particle definition, and enabling steam generation from recovered energy, the SCHACK® Air Preheater is a critical component for maximizing output, product quality, and overall profitability in modern carbon black plants.
Your Benefits
SCHACK® Quench Boilers are positioned within the carbon black process directly downstream of the reactor in which the quench process takes place. The main function of quench boilers is to generate high-pressure steam by cooling down process gas, for example from 1,400 °C to 1,000 °C (2,552 °F to 1,832 °F).
The cooling temperature window is adjusted to the inlet temperature of the air preheater connected downstream.
SCHACK® Quench Boiler design is based on the approved SCHMIDT’SCHE® Double Tube & Oval Header technology platform for extremely high thermal loads.
The heat recovered from the carbon black gas is used by the SCHACK® Quench Boiler to generate saturated steam.
The SCHACK® Quench Boiler is not sensitive to fouling particles and exhibits high mechanical reliability.
Your Benefits
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