Carbon Black Formation and Suppression in Pyrolysis Reactor Off-Gas Treatment Systems

Abstract

Carbon black formation during pyrolysis-based waste conversion and thermochemical processing has emerged as a critical challenge affecting reactor efficiency, downstream equipment reliability, environmental compliance, and product gas quality. The present study investigates the mechanisms responsible for carbon black generation in pyrolysis reactor off-gas treatment systems and evaluates effective suppression strategies for minimizing particulate deposition and operational instability. Emphasis is placed on the influence of reactor temperature, residence time, feedstock composition, gas-phase cracking reactions, and hydrocarbon condensation phenomena on soot precursor development and particle nucleation. Experimental observations and process analyses demonstrate that elevated thermal gradients and incomplete secondary cracking significantly accelerate carbonaceous particle formation, leading to fouling, pressure drops, and reduced heat transfer efficiency in gas cleaning units. Various suppression techniques, including optimized temperature control, staged oxidation, catalytic reforming, cyclone separation, and advanced filtration systems, are critically assessed for their capability to reduce carbon black accumulation while maintaining syngas quality and energy recovery efficiency. The study further highlights the role of reactor design modifications and real-time monitoring approaches in improving operational sustainability and reducing maintenance requirements. Comparative performance evaluation indicates that integrated catalytic and thermal management strategies provide substantial reductions in particulate emissions and enhance overall system stability.