Carbon blacks having low PAH amounts and methods of making same

1. A carbon black having a low PAH content, wherein the PAH content is determined based on a PAH22 content, said carbon black is a furnace carbon black and has a STSA, I 2 No/STSA ratio, and PAH content as follows:

a) STSA: 110-250 m 2 /g

I 2 No (mg/g)/STSA (m 2 /g): 1.20 to 0.70

PAH: 400 ppm or less; or

b) STSA: 80-110 m 2 /g

I 2 No (mg/g)/STSA (m 2 /g): 1.15 to 0.70

PAH: 30 ppm or less; or

c) STSA: 65-75 m 2 /g

I 2 No (mg/g)/STSA (m 2 /g): 1.10-0.88

PAH: 500 ppm or less

DBP: 115-125 mL/100 g; or

d) STSA: 65-80 m 2 /g

I 2 No (mg/g)/STSA (m 2 /g): 0.70 to 0.88

PAH: 500 ppm or less; or

e) STSA: 1 to 35 m 2 /g

I 2 No (mg/g)/STSA (m 2 /g): 1.40 to 0.70

PAH: 50 ppm or less; or

f) STSA: 70 to 90 m 2 /g

I 2 No (mg/g)/STSA (m 2 /g): 1.00 to 1.20

PAH: 50 ppm or less

DBP: 60-80 mL/100 g; or

g) STSA: 87-95 m 2 /g

I 2 No (mg/g)/STSA (m 2 /g): 0.91 to 1.08

PAH: 100 ppm or less

DBP: 109-119 mL/100 g,

wherein said carbon black has one or more of the following mechanical properties or rubber properties when included in a rubber formulation according to ASTM D 3191-02:

abrasion resistance (21% slip) of from 80 to 170;

elongation (%) of from 300 to 600;

tensile strength (Mpa) of from 20 to 35;

100% modulus (Mpa) of from 2.4 to 4.5;

300% modulus (Mpa) of from 12 to 23;

ratio of 300% modulus/100% modulus (M300%/M100%) of from 3.5 to 6;

bound rubber (%) of from 15 to 30; and/or

max tan delta @ 0° C. of from 0.25 to 0.4.

2. The carbon black of claim 1 , wherein said carbon black is a) and has an I 2 No (mg/g)/STSA (m 2 /g) of 1.15 to 0.70.

3. The carbon black of claim 2 , wherein said carbon black has a STSA of 110 to 200 m 2 /g.

4. The carbon black of claim 2 , wherein said carbon black has a STSA of 110 to 175 m 2 /g.

5. The carbon black of claim 4 , wherein said carbon black has a PAH content of 1 ppm to 200 ppm.

6. The carbon black of claim 4 , wherein said carbon black has a PAH content of 1 ppm to 50 ppm.

7. The carbon black of claim 4 , wherein said carbon black has a PAH of 1 ppm to 150 ppm.

8. The carbon black of claim 4 , wherein said carbon black has a PAH content of 1 ppm to 100 ppm.

9. The carbon black of claim 4 , wherein said carbon black has a PAH of 20 ppm or less.

10. The carbon black of claim 2 , wherein said carbon black has a STSA of 110 to 150 m 2 /g.

11. The carbon black of claim 2 , wherein said carbon black has a I 2 No/STSA of 1.15 to 0.9.

12. The carbon black of claim 1 , wherein said carbon black is b) and said I 2 No/STSA is 1.10 or less.

13. The carbon black of claim 12 , wherein said PAH content is 1 ppm to 20 ppm.

14. The carbon black of claim 12 , wherein said PAH content is 10 ppm or less.

15. The carbon black of claim 1 , wherein said carbon black is c).

16. The carbon black of claim 15 , wherein said PAH content is 1 ppm to 100 ppm.

17. The carbon black of claim 1 , wherein said carbon black is d).

18. The carbon black of claim 17 , wherein said PAH content is 1 ppm to 300 ppm.

19. The carbon black of claim 17 , wherein said PAH content is 1 ppm to 150 ppm.

20. The carbon black of claim 17 , wherein said PAH content is 1 ppm to 100 ppm.

21. The carbon black of claim 17 , wherein said PAH content is 1 ppm to 50 ppm.

22. The carbon black of claim 17 , wherein said PAH content is 20 ppm or less.

23. The carbon black of claim 1 , wherein said carbon black is e).

24. The carbon black of claim 23 , wherein said PAH content is 1 ppm to 20 ppm.

25. The carbon black of claim 23 , wherein said PAH content is 10 ppm or less.

26. The carbon black of claim 1 , wherein said carbon black is f).

27. The carbon black of claim 26 , wherein said carbon black has a DBP of 72 mL/100 g, an STSA of 76 m 2 /g, and an I 2 No/STSA of 1.05 to 1.09, and PAH content of 50 or less.

28. The carbon black of claim 26 , wherein the DBP is 66-77 mL/100 g or less.

29. The carbon black of claim 26 , wherein said DBP is 60 mL/100 g to 72 mL/100 g.

30. The carbon black of claim 26 , wherein said PAH content is 1 ppm to 20 ppm.

31. The carbon black of claim 26 , wherein said PAH content is 10 ppm or less.

32. A method to produce the carbon black of claim 1 , said method comprising subjecting or treating a carbon black having a PAH content to/with sufficient heat, optionally in an inert or vacuum atmosphere, such that the PAH or a portion thereof is removed to form said carbon black.

33. The method of claim 32 , wherein said heat is on the order of from about 300° C. to about 950° C.

34. A method to produce the carbon black of claim 1 , said method comprising subjecting a carbon black having a PAH above 500 ppm to one or more solvent extractions.

35. A method to produce the carbon black of claim 1 , wherein during manufacturing of carbon black involving the presence of hot tail gas containing a carbon black and PAH, said method comprising removing said hot tail gas with PAH from said carbon black.

36. The method of claim 35 , wherein said removing of said hot tail gas is at a temperature of from about 260° C. to about 950° C.

37. The method of claim 35 , wherein said removing of said hot tail gas is at a temperature of from about 500° C. to about 900° C.

38. The method of claim 35 , wherein said carbon black is a furnace carbon black and said method occurs in a furnace carbon black reactor.

39. The method of claim 35 , wherein a cyclone is used to remove said hot tail gas from said carbon black.

40. The method of claim 35 , wherein a high temperature filter is used to remove said hot tail gas from said carbon black.

41. The method of claim 35 , wherein after separating said carbon black from said hot tail gas, said carbon black has a carbon black temperature above 200° C., and said method further comprising lowering the carbon black temperature to below 200° C. prior to introducing said carbon black into a bag filter.

42. The method of claim 35 , wherein after separating said carbon black from said hot tail gas, said carbon black has a carbon black temperature above 400° C., and said method further comprising lowering the carbon black temperature to below 400° C. prior to introducing said carbon black into a bag filter.

43. The method of claim 35 , wherein said PAH remains in a gas phase and does not condense of said carbon black.

44. The method of claim 43 , wherein said recycling comprises re-using said hot tail gas in a carbon black manufacturing process.

45. The method of claim 43 , wherein said recycling comprises re-using said hot tail gas as a heat source.

46. The method of claim 45 , wherein said hot tail gas is used as at least a partial heat source for a dryer.

47. The method of claim 45 , wherein said dryer is a carbon black dryer.

48. The method of claim 45 , wherein said dryer is operated at a sufficient temperature such that the PAH in said hot tail gas is destroyed.

49. The method of claim 35 , further comprising recycling said hot tail gas with PAH.

50. The carbon black of claim 1 , wherein said carbon black has a PAH content of from about 0.15 to about 2 micrograms/m 2 .

51. The carbon black of claim 1 , wherein said carbon black is a rubber grade or tire grade carbon black.

52. The carbon black of claim 1 , wherein said carbon black is a N110-N787 ASTM carbon black.

53. A carbon black having a low PAH content, wherein the PAH content is determined based on a PAH22 content, said carbon black is a furnace carbon black and has a STSA, I2No/STSA ratio, and PAH content as follows:

a) STSA: 110-250 m 2 /g

I 2 No (mg/g)/STSA (m 2 /g): 1.20 to 0.70

PAH: 400 ppm or less; or

b) STSA: 80-110 m 2 /g

I 2 No (mg/g)/STSA (m 2 /g): 1.15 to 0.70

PAH: 30 ppm or less; or

c) STSA: 65-75 m 2 /g

I 2 No (mg/g)/STSA (m 2 /g): 1.10-0.88

PAH: 500 ppm or less

DBP: 115-125 mL/100 g; or

d) STSA: 65-80 m 2 /g

I 2 No (mg/g)/STSA (m 2 /g): 0.70 to 0.88

PAH: 500 ppm or less; or

e) STSA: 1 to 35 m 2 /g

I 2 No (mg/g)/STSA (m 2 /g): 1.40 to 0.70

PAH: 50 ppm or less; or

f) STSA: 70 to 90 m 2 /g

I 2 No (mg/g)/STSA (m 2 /g): 1.00 to 1.20

PAH: 50 ppm or less

DBP: 60-80 mL/100 g; or

g) STSA: 87-95 m 2 /g

I 2 No (mg/g)/STSA (m 2 /g): 0.91 to 1.08

PAH: 100 ppm or less

DBP: 109-119 mL/100 g

wherein said carbon black has the ability to impart at least one mechanical property in a rubber matrix, or an elastomeric composition, said at least one mechanical property is one or more of the following:

abrasion resistance (21% slip)—,

elongation (%)—ASTM D 3191-02 Standard Test Methods for Carbon Black in SBR—Recipe and Evaluation Procedures,

tensile strength (Mpa); ASTM D 3191-02 Standard Test Methods for Carbon Black in SBR—Recipe and Evaluation Procedures,

100% modulus (Mpa); ASTM D 3191-02 Standard Test Methods for Carbon Black in SBR—Recipe and Evaluation Procedures,

300% modulus (Mpa); ASTM D 3191-02 Standard Test Methods for Carbon Black in SBR—Recipe and Evaluation Procedures,

ratio of 300% modulus/100% modulus (M300%/M100%); ASTM D 3191-02 Standard Test Methods for Carbon Black in SBR—Recipe and Evaluation Procedures,

bound rubber (%); or

max tan delta @ 0° C. tested with ARES/Rheometrics Dynamic Spectrometer II (RDS II, Rheometrics, Inc., N.J) operated in a torsion strain mode (shear) with measurements performed at 0° C. for strain sweeps with double strain amplitude (DSA) ranging from 0.2 to 120%, at a constant frequency of 10 Hz, and

wherein at least one of said mechanical properties for said carbon black is within 10% of the value for the same mechanical property for the same type of carbon black having a PAH22 content of 600 ppm to 1,000 ppm.