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Friday, May 7, 2010

Carbon black

Hi Tech Carbon (India)
Hi Tech Carbon is a unit of Aditya Birla Nuvo Ltd., a flagship company in the fold of Aditya Birla Group of companies. Hi Tech Carbon is the second largest producer of Carbon Black in India. The company started with a modest beginning in 1988 at Renukoot, and has never looked back since. With manufacturing facilities at Renukoot in Uttar Pradesh and Gummidipoondi in Tamil Nadu, the combined capacity stands at 240,000 tpa.

Hi Tech Carbon exports roughly one-third to customers in the international market. The company enjoys 33 per cent of the domestic market share. Apart from the domestic Indian market, overseas markets in Bangladesh, Japan, Indonesia, Nepal, Philippines, Sri Lanka, Vietnam, UAE, and Singapore are being catered to on a regular basis.

Hi Tech Carbon uses the most modern technology, operated through the Distributed Control System (DCS). This process automation ensures quality and consistency in the manufacturing of Carbon Black. The manufacturing process also envisages conserving heat energy for productive utilisation through downstream processes. The energy conserved is converted into power for utilisation both captively and exported to the state grid.

Hi Tech Carbon is the first organisation in the world to be awarded ISO 9002, ISO 14001 and QS 9000 certification within the first year of plant operation. The company has internalised management techniques such as 5-S, QSS, KSS, Mentor, IQRS, Six Sigma and Total Productive Maintenance (TPM) practices to enrich operational performance. Hi Tech Carbon is also the first Carbon Black plant to be certified with OHSAS- 18001 for occupational health and safety. The Carbon Black unit at Gummidipoondi has won the coveted Deming Award for Quality (2002) conferred by the Deming Prize Committee (JUSE), Japan.

The quality assurance and technical services laboratory is equipped with the most advanced technical facilities and is manned by highly experienced and qualified personnel.

Hi Tech Carbon is one of the lowest cost producers and has the locational advantage of being near the sea coast. The company is expanding its capacity by 55,000 tpa at a cost of Rs.120 crore at Gummidipoondi. It is further exploring Greenfield expansion of 60,000 tpa in Western India.
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Management team
Birla Carbon
Safety, health and environment


General enquiries | Alexandria Carbon Black | Hi Tech Carbon
Liaoning Birla Carbon | Thai Carbon Black

General enquiries
Corporate Office — Carbon Black Business
Aditya Birla Centre
S K Ahire Marg, Worli
Mumbai 400 030
Phone: (91) 22 6652 5000 / 2499 5000
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Alexandria Carbon Black, Egypt
Mr. Sabyasachi Patnaik
El Nahda Road
Amreya 23511
Alexandria, Egypt
Tel: (203) 4770 102 / 4770 107
Fax (203) 4770 110
Cairo office (Marketing and commercial)
26th floor, Suez Canal Tower
4 - Ebn Kathir (Nile) Street, Giza
Cairo, Egypt
Tel: (202) 337 3870 / 336 6461
Belgium sales office
ACB Belgium BVba
Mr.Serge Klunder
Polder 3,
B-2840 Rumst
Tel: +323 888 8085
Mob : +324 757 62556
Fax: (32-3) 888 80 85

UK sales office
Unit 1, Four Ashes Business Park
Station Road, Four Ashes
Wolver Hampton WV10 7DB
Tel: (44-1902) 791850
Fax: (44-1902) 790560

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Hi Tech Carbon, India (unit of Aditya Birla Nuvo Ltd.)
Renukoot plant
Murdhawa Industrial Area
P.O. Renukoot
Dist. Sonebhadra
Uttar Pradesh 231 217
Tel: (91) 5446 252 387-91
Gummidipoondi plant
K-16, Phase II, Dist. Thiruvallur
SIPCOT Industrial Complex
Gummidipoondi 601 201
Tamil Nadu
Tel: (91) 44 2798 9233 / 6

Birla Carbon

Birla Carbon vision: To be the most respected, green, global, advanced fillers business with a clear focus on tyre and MRG markets

The Aditya Birla Group's Carbon Black business spans four companies in four countries. The Group's four Carbon Black companies are
Alexandria Carbon Black in Egypt, Hi Tech Carbonin India, Thai Carbon Black in Thailand and Liaoning Birla Carbonin China.

Located at Alexandria in Egypt, Alexandria Carbon Black is an Indo-Egyptian joint venture of the Aditya Birla Group with the Egyptian Government. With a capacity of 285,000 mtpa, the company is one of the fastest growing Carbon Black in the world.

Thai Carbon Black has been listed among the world's best 200 small companies for three years from 2002 to 2005. With an annual capacity of 210,000 mt, Thai Carbon Black supplies to markets in South East Asia, Australia and some European countries.

With manufacturing plants at Renukoot in U.P and Gummidipoondi in Tamilnadu, Hi Tech Carbon is the second largest producer of Carbon Black in India. The company has a combined capacity of 240,000 mtpa and exports about one third of its production overseas.

Liaoning Birla Carbon, a pioneering venture in China, is a joint venture between Thai Carbon Black Co. Ltd. and Dashiqiao Ronghua Co. Ltd. With a capacity of 55,000 mtpa, the company uses the distributed control system (DCS) to ensure consistency of quality.

With a total annual capacity of 790,000 mt, the Aditya Birla Group is the fourth largest producer of Carbon Black in the world. The four companies work in synergy to produce world-class Carbon Black. The varied locations give the companies access to most of the world's markets.

The Carbon Black business is directly influenced by the tyre industry, which is driven by the automobile industry. The automobile industry also influences the non-tyre segment since a significant portion of this segment includes components for the automobile industry. The macro economic factor impacting the automobile industry is GDP per capita. The European Carbon Black market is about 1.4 million mtpa and is growing at a rate of about 1 per cent while the Asian markets are growing at over 5 per cent with a total of 1.6 million mtpa.

With sales offices in India (Delhi, Mumbai, Kolkata), Thailand(Bangkok), China (Dashiqiao), Egypt (Cairo), United Kingdom(Wolver Hampton) and Belgium (Antwerp), the Group's Carbon Black companies cater to markets in United Kingdom, Spain, France, Israel, Turkey, Morocco, Ethiopia, Thailand, India, Japan, Indonesia, Philippines, Malaysia, China, Korea, Taiwan, Australia, Sri Lanka, Bangladesh, Vietnam, UAE, Singapore and Nepal.


Carbon black

From Wikipedia, the free encyclopedia

Worker at a Texas carbon black plant (photo by John Vachon, 1942)

Carbon black is a material produced by the incomplete combustion of heavy petroleum products such as FCC tar, coal tar, ethylene cracking tar, and a small amount from vegetable oil. Carbon black is a form of amorphous carbon that has a high surface-area-to-volume ratio, although its surface-area-to-volume ratio is low compared to that of activated carbon. It is dissimilar to soot in its much higher surface-area-to-volume ratio and significantly less (negligible and non-bioavailable) PAH (polycyclic aromatic hydrocarbon) content. Carbon black is used as a pigment and reinforcement inrubber and plastic products.

The current International Agency for Research on Cancer (IARC) evaluation is that, "Carbon black is possibly carcinogenic to humans (Group 2B)". Short-term exposure to high concentrations of carbon black dust may produce discomfort to the upper respiratory tract, through mechanical irritation.




Manufacturing Process of Carbon Black

Classification of carbon black by manufacturing process

Carbon black is produced with the thermal decomposition method or the partial combustion method using hydrocarbons such as oil or natural gas as raw material.
The characteristics of carbon black vary depending on manufacturing process, and therefore carbon black is classified by manufacturing process. Carbon black produced with the furnace process, which is the most commonly used method now, is called “furnace black,” distinguishing it from carbon black, which is manufactured with other processes.

Furnace Black Process

This method forms carbon black by blowing petroleum oil or coal oil as raw material (feedstock oil) into high-temperature gases to combust them partially. This method is suitable for mass production due to its high yield, and allows wide control over its properties such as particle size or structure. This is currently the most common method used for manufacturing carbon black for various applications from rubber reinforcement to coloring.

Channel Process

This method forms carbon black by bringing partially combusted fuel, which is generated with natural gas as raw material, into contact with channel steel (H-shaped steel) and then collecting the carbon black which results.
There are yield and environment issues around this method, and therefore has lost the leading role as the mass production process to the furnace process. This method, however, provides carbon black with many functional groups on the surface, being used in some painting applications.

Acetylene Black Process

This process obtains carbon black by thermally decomposing acetylene gas. It provides carbon black with higher structures and higher crystallinity, and is mainly used for electric conductive agents.

Lampblack Process

This method obtains carbon black by collecting soot from fumes generated by burning oils or pine wood.
This method has been used since the days before Christ, and is not suitable for mass production. However, it is used as raw material for ink sticks as it provides carbon black with specific color.




Alexandria Carbon Black Co SAE (Egypt)
Alexandria Carbon Black Company SAE holds the distinction of being one of the world's largest Carbon Black plants at a single location. The company, an Indo-Egyptian joint venture of the Aditya Birla Group, is the only producer of Carbon Black in the Middle East and North African region.

Established in 1994 with an initial capacity of 20,000 tpa with technology from Continental Carbon (USA), the company has grown more than 10 times to 285,000 tpa, making it the world's largest Carbon Black plant at a single location. It is the fastest growing Carbon Black company in the world.

The company produces various grades of Carbon Black used mainly in the rubber industry. About 80 per cent of the world's Carbon Black production is utilised by the tyre industry. It is also used in the manufacture of inks, dyes, paints, cables and plastics.

Marketed under the brand name Birla Carbon, the company exports 95 per cent of its Carbon Black produce to over 50 countries across the globe including the US, UK, France, Germany, Italy, Spain, among others.

In line with the high quality standards maintained across the Group, Alexandria Carbon Black has led the way in the Carbon Black industry and among industries in Egypt, Middle East and North Africa. It has achieved QS-9000 accreditation for Quality Management System, ISO 14001 certification for Environment Management, OHSAS 18001 accreditation for Occupational Health & Safety Standards and presented the Special Award for TPM achievement from JIPM, Japan.

Alexandria Carbon Black also has the distinction of being ISO-TS 16949 certified along with SA 8000 Accreditation for Social Accountability. It has been a recipient of the international Safety Award by the British Safety Council and was ranked among the five best environment friendly companies, worldwide by IFC.

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chlor alkali | epoxy | phosphates | sulphites

Aditya Birla Chemicals (Thailand) Limited forms part of the Aditya Birla Group's chemicals business, which spans over nine units — five in Thailand and four in India. The company is engaged in the production of five major chemical groups, namely, chlor-alkali products, epichlorohydrin, epoxy resins, phosphates and sulphites.

Aditya Birla Chemicals (Thailand) Limited has built a strong business in Thailand and also exports its products to 58 countries across the globe. It serves customers in a large number of industries such as food, food processing, personal consumer products, paints, textiles, pulp and paper, detergents, water treatment, metal treatment and more.

Chlor alkali division
The division commenced production of chlor-alkali products and epichlorohydrin in 1998. The technology of the chlor- alkali plant is from Asahi Glass of Japan and that of epichlorohydrin from Stork Comprimo of Belgium. The plant has a capacity to manufacture 15,000 mt of epichlorohydrin and 80,000 dmt of caustic soda. In 2006, the division commissioned its new caustic soda plant of capacity 21,000 dmt based on the latest membrane technology from UHDE.

Excellent product quality has enabled the unit to capture a sizeable share of the market in Thailand in chlor-alkali products, with most of the country's leading multinational consumers as its customers. The unit has extended its reach to South East Asia and has been exporting chlorine regularly.

Epichlorohydrin, manufactured by the unit, is largely supplied to its Epoxy division for the manufacture of epoxy resins. The unit has also developed an international market for the sale of allylchloride in India and epichlorohydrin to the U.S., Europe, Indonesia, Australia and New Zealand.

The unit has ISO 9001:2000, ISO14001, OSHAS 18001, BS 8800 and TIS 18001 certifications.

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Epoxy division
The Epoxy division is a pioneer in the manufacture of epoxy resins in South East Asia. It started commercial production in 1992 at Rayong, Thailand. The modern ISO 9001 and ISO 14001 certified plant uses state-of-the-art technology from Tohto Kasei, the largest epoxy producer in Japan. Sophisticated machinery, Distributed Control Systems (DCS) and a fully equipped quality assurance laboratory enable the unit to produce consistently high quality epoxy resins. The unit was awarded the TPM Excellence (first category) by Japan Institute of Plant Maintenance (JIPM), Japan in 2004.

The Epoxy division has grown from 10,000 tpa to 37,500 tpa over a period of 13 years. In 2004, it installed dedicated production facilities for speciality epoxies, reactive diluents and hardeners with capacity of 5000 tpa. During 2007, the Epoxy division implemented de-bottlenecking of its existing production lines and set up dedicated facilities to produce water borne epoxies, radiation cure epoxies, diluents, hardeners and bis-f and novolac pre-cursers and epoxies. In July 2008, the division commissioned a high performance epoxy adhesive system plant with state-of-the-art facilities to serve the growing needs of wind energy industry. These plans have taken the total capacity of the division to over 65,000 tpa.

The new products will further strengthen it’s position as a provider of a wide range of speciality products. The division has also set up a 9000 sq. ft R&D and Application Centre for accelerating product development, application testing and providing more technical services to customers.

With its vision "to become the preferred source of performance epoxy products and solution provider for global composites and coating industry", the Epoxy division with its modern R&D and Application Centre facilities has moved from being a 'product supplier' to a 'solutions provider', working closely with customers to provide superior value through customised products, speciality formulations and systems.

The division produces a wide range of epoxies, hardeners and modifiers that vary in the chemical structure, molecular weight, viscosity and functionality. Marketed under the brand name EPOTEC, its product range has liquid, solid, solutions, blends and other multifunctional epoxy resins. These products are used across a wide array of applications like automotive, construction and heavy engineering, transport, electrical and electronics, food and beverage packing, coatings, composites, adhesives, aviation and aerospace, wind-energy, etc.

Exporting over 75 per cent of its output, its products reach out to over 40 countries worldwide, with a major share going to the quality conscious markets in the USA and Europe.

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Phosphates division
The Phosphate division is currently the world's leading manufacturer of high quality food grade sodium and potassium phosphates. Commissioned in 1984 to produce POLYPHOS (sodium tripolyphosphate), it has, over the years, enhanced capacity to 85,000 tpa through de-bottlenecking by more than 100 per cent and earned a reputation as one of the most efficient and reliable suppliers of high quality speciality phosphates.

The phosphates are mainly being used as meat and seafood preservatives, leavening in bakery products, emulsifiers and stabilisers in dairy products and builders in detergents. Phosphates are also used in the manufacture of animal
feeds, toothpaste, textile dyes, starches and ceramic tiles, as well as in water and metal treatment, and as stabilisers in chemical processes. Speciality phosphates such as MPSeaphos and non-phosphate such as NP-Seapure provide superior yield, texture and colour during the processing of raw and cooked shrimps, fish and squids.

Current exports account for 26 per cent of production to 38 countries including Japan, Australia, New Zealand, Indonesia, Spain and USA, and other countries in the South East Asian region.

The Phosphates division was the first manufacturer of sodium phosphates in the Asia Pacific to be ISO 9000 certified for its quality management systems, and the first sodium phosphate manufacturer in the world to be accredited with ISO 14001. Constant upgrading of technology has also enabled the company to receive the prestigious Prime Minister's Industry Award for outstanding performance in environmental conservation. Additional achievements include the award for TPM Excellence for (1st category and Consistent Award); TIS 18001; SAP software implementation; Thailand Quality Prize, and GMP, HACCP, Halal and Kosher accreditation.

The division’s enviable record of manufacturing excellence and quality management remains unmatched in the South East Asian region.

Future plans include additional investments and capacity expansions for food grade blends and R&D facility. A backward integration project for manufacturing phosphoric acid in China is at an advanced stage.

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Sulphites division
Set up in 1995, the state-of-the-art manufacturing plant is located in the Saraburi province. The Sulphites division manufactures sodium sulphite, sodium metabisulphite, sodium bisulphites solution and catalysed sodium sulphite. With an annual capacity of 75,000 mt, it is among the world's top three high quality producers of these chemicals. The capacity is slated to increase to 80,000 mt in 2008.

The company's products are marketed under the brand names 'BIRLASULF-SS' and "BIRLASULF-SM" and are used primarily in photographic, food, water treatment, pulp and paper, leather, textiles, acrylic fibre, mining, chemical and pharmaceutical industries.

The Sulphites division has also developed value-added liquid sodium bisulphite that is marketed under the brand name "BIRLASOL - 35" in the domestic starch pulp and paper and mining industries.

The Sulphites division is also launching potassium metabisulphites to serve the wine market in Europe and Australia.

It has earned the reputation of being the "Preferred Supplier" for many global customers with its products being exported across 44 countries.

Certified for ISO 9001, 14001, OHSAS 18001, THAI-FDA and HALAL, the company was conferred with the Thailand Prime Minister's award for "Outstanding Industry for year 2000" and has been awarded TPM Excellence (first category) by the Japan Institute of Plant Maintenance (JIPM), Japan in 2002.

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