Carbon black is a form of finely divided carbon produced by incomplete combustion or thermal decomposition of hydrocarbons (like oil or natural gas). It is a common material used as a black pigment in inks and paints, as a reinforcing filler in rubber products such as tires, and as a key ingredient in batteries and other materials requiring high conductivity.

How Carbon Black is Made:

Feedstock Selection: Typically, carbon black is produced from heavy petroleum products such as FCC tar, coal tar, ethylene cracking tar, and other sources rich in hydrocarbons.

Formation Process:
Furnace Process: The most common method involves combusting a hydrocarbon fuel (like natural gas or oil) with a limited supply of air inside a furnace. This incomplete combustion produces a fine carbonaceous powder.
Channel Process: In this method, liquid hydrocarbons are burned in a series of open-ended channels, resulting in carbon black particles forming on the channel walls.

Particle Formation: During combustion, the carbon-containing feedstock undergoes pyrolysis (thermal decomposition in the absence of oxygen), forming fine particles of carbon black.

Collection and Processing: The carbon black particles are cooled and then collected using filtration techniques. They are often further processed to control particle size, surface area, and other properties, depending on their intended applications.

Differences from Charcoal:

Charcoal, on the other hand, is produced through the controlled burning of wood (or other organic matter) in the absence of air (pyrolysis). The key differences between carbon black and charcoal include:

Production Method: Charcoal is made from wood through pyrolysis, whereas carbon black is produced from hydrocarbons through incomplete combustion.

Composition and Use: Charcoal is primarily composed of carbon and is used as a fuel and in cooking, whereas carbon black is composed of fine carbon particles and is used mainly as a pigment and reinforcing filler in industrial applications.

Particle Size and Structure: Carbon black particles are extremely fine (nanometer scale), whereas charcoal particles can vary widely in size and structure depending on the source material and production method.

In summary, while both carbon black and charcoal are forms of carbon produced through thermal processes, they differ significantly in terms of production methods, composition, and applications.