Improving reactor efficiency isn’t just about operating hotter—it’s about doing so safely and sustainably. For example, increasing reactor temperatures from 1,850°C to 2,200°C can improve yield by up to 3-5%. This means more product output for the same energy and feedstock input, directly enhancing the energy efficiency and yield of the process.
However, these gains are only achievable with refractories capable of handling extreme thermal stress while maintaining dimensional and structural integrity. Materials such as sintered alumina and fused zirconia offer the required thermal stability, shock resistance, and corrosion resistance to support these demanding conditions.
Additionally, longer-lasting refractories minimize shutdowns, which are not only costly but also lead to energy losses during cooling and reheating cycles.

In carbon black manufacturing, reactor design and material needs vary depending on the application:

• Tread reactors produce carbon black used in the outer layer of tyres, demanding high wear resistance.
• Carcass reactors generate carbon black for the structural part of the tyre, where strength and stability are key.

Refractories must be engineered accordingly—not only to withstand the physical stresses of the environment but also to support consistent production quality across different reactor zones such as the combustor, choke, and venturi.

As carbon black producers strive to cut emissions, refractory manufacturers must also reduce their own environmental footprint. This includes:

• Transitioning to cleaner fuels such as natural gas and electricity.
• Optimizing refractory production processes for energy efficiency.
• Lowering Scope 3 emissions through cleaner energy sourcing and raw material supply chains.

These steps are crucial in ensuring that the benefits of improved reactor efficiency are not offset by emissions elsewhere in the supply chain.

With decades of experience in the carbon black industry, Saint-Gobain has developed specialized refractories that meet the evolving performance and sustainability needs of manufacturers. From tailored materials to collaborative product development, we support the shift toward more efficient and responsible carbon black production.

• Higher Yields with improved thermal efficiency
• Reduced Emissions through energy savings and longer refractory lifespan
• Faster Maintenance with innovative, single-piece refractory designs
• Cleaner Operations using low-emission fuels and greener energy
• Reliable Expertise from decades of industry collaboration