CASE STUDIES: Commercial production of specification-grade recovered carbon black

The recovered carbon black (rCB) industry has achieved a critical turning point between 2020-2025, with multiple companies demonstrating commercial-scale production meeting ASTM D8474 specifications for N300-N600 grades. This comprehensive analysis reveals over 20 industrial implementations across North America, Europe, and Asia-Pacific, with documented quality achievements and tire manufacturer validation.

North American implementations demonstrate commercial viability

Three major North American producers have established industrial-scale operations producing specification-grade rCB.

Delta Energy Group's Natchez, Mississippi facility stands as the continent's most mature operation, processing 100 tons of scrap tires daily to produce 11,000 tons of rCB annually. Their Phoenix Black® and Zephyr Black® products have achieved remarkable commercial success through their partnership with Bridgestone, with 6,800 metric tons supplied by 2020, demonstrating an 81% CO₂ reduction compared to virgin carbon black production.

Klean Industries, headquartered in Vancouver, represents the most ambitious North American expansion, with planned facilities totaling 225,000 metric tonnes of tire processing capacity. Their CBk KleanCarbon product line includes grades specifically designed to replace N300, N600, and N700 series virgin carbon blacks. As active voting members of ASTM Committee D36, Klean's leadership contributed directly to developing the D8474 standard for thermogravimetric analysis of rCB.

The Terre Haute, Indiana facility, originally operated by Pyrolyx and now owned by Bolder Industries following a $55 million investment, demonstrates the evolution of the industry. The facility's four-reactor configuration targets 10,000 metric tons of rCB production annually, with products refined into semi-reinforcing grades including N500, N600, and N700. Their jet mill processing achieves particle sizes below 10 μm, enabling an average 30% replacement rate in virgin carbon black applications.

European producers lead in quality specifications and partnerships

European companies have achieved the most detailed quality specifications and strongest tire manufacturer partnerships. Black Bear Carbon's Nederweert facility in the Netherlands produces 12,000 tons annually of rCB with exceptional quality metrics: greater than 94% carbon content and less than 5 ppm PAH content, making it suitable even for food contact applications. Their proprietary post-treatment upgrading technology achieves performance grades equivalent to N300-N600 series, with particle sizes ranging from 7-36 μm in ground form.

Scandinavian Enviro Systems has leveraged its strategic partnership with Michelin to establish commercial credibility. Their Åsensbruk plant, operational since 2019, achieved the world's first ISCC certification for rCB, demonstrating a 93% CO₂ reduction versus virgin carbon black production. The company's joint venture with Antin Infrastructure Partners targets 1 million tons of end-of-life tire processing capacity by 2030, with five European facilities planned.

Pyrum Innovations in Germany has achieved remarkable commercial traction since beginning operations in May 2020. Their Dillingen facility has processed over 7,000 tons of end-of-life tires, with expansion to 20,000 tons annual capacity underway. Critical partnerships include Continental AG for long-term rCB supply and BASF SE as both a 7.9% shareholder and pyrolysis oil customer. Pyrum holds the distinction of achieving the first REACH registration in the tire recycling sector in 2018.

The Circtec-Birla Carbon partnership represents the largest planned European capacity, with their Delfzijl, Netherlands facility targeting 200,000 tons of tire processing annually. By partnering with Birla Carbon, the world's largest carbon black producer, Circtec gains access to technical expertise for producing their Continua™ Sustainable Carbonaceous Materials meeting ASTM specifications.

Asia-Pacific operations scale rapidly with technical innovation

Asian producers demonstrate significant scale and technical capabilities. Enrestec's Taiwan facility processes 36,000 tons annually with a remarkable 99% conversion rate using patented continuous pyrolysis technology. As the first commercial chemical plant in Asia certified with ISCC Plus, Enrestec has expanded to Thailand with a 100,000-ton capacity facility, producing rCB meeting stringent standards for plastics and industrial rubber products.

Epsilon Carbon in India operates 115,000 metric tons of virgin carbon black capacity and recently entered the tire-derived rCB market with their January 2025 launch of Terrablack, a sustainable product line using recovered carbon black and tire-derived oil. Following 24 months of development, Epsilon Carbon is constructing a fully integrated tire recycling facility in Karnataka, operational by FY26, which will process 30,000 tons of end-of-life tires annually to produce 9,500 tons of rCB and 12,000 tons of TDO. Their commitment to reducing global warming potential by 40-50% aligns with India's extended producer responsibility standards.

Multiple Korean producers including OCI Company Ltd. operate facilities with combined capacities exceeding 420,000 metric tons annually, though specific rCB production volumes require further differentiation from virgin carbon black operations.

Process parameters and purification methods achieve specifications

Industrial implementations employ various reactor configurations and process parameters to achieve ASTM D8474 specifications. Continuous rotary kiln systems operate at controlled pyrolysis temperatures, with residence times optimized for carbon black recovery. Higher heating rates shift production toward oil yield, while controlled temperature profiles maximize fixed carbon content in the rCB product.

Critical purification innovations enable achievement of N300-N600 specifications. RCB Nanotechnologies' wet chemical treatment achieves 96% carbon content with sub-10 micron particle sizes matching virgin carbon black quality. Acid-base demineralization using HCl treatment reduces ash content from 15% to 4.9%, qualifying products for N550 substitution. Advanced microwave-assisted processing with HCl/HF dual reagents achieves 92.10 m²/g surface area, qualifying for N326 replacement applications.

Commercial validation through tire manufacturer adoption

Major tire manufacturers have validated rCB quality through commercial implementation. Continental began using rCB in SC20+ solid tires in 2023, achieving 60% renewable/recycled content. Bridgestone's multi-plant usage across Des Moines Agriculture, Aiken County Passenger, and Cuernavaca facilities demonstrates broad applicability.

Michelin achieved 63% sustainable materials in Le Mans 2023 racing tires and maintains a 20% stake in Enviro Systems.

Schwalbe's bicycle tire success represents the most complete implementation, with 70% of their product range now using Pyrum rCB. This closed-loop system recycled 940,000 bicycle tires while achieving 80% CO₂ reduction versus virgin carbon black.

Published documentation confirms technical achievements

Technical validation appears in numerous peer-reviewed publications and industry reports. A 2025 paper by Bogdahn et al. in Advanced Materials & Sustainable Manufacturing confirms rCB properties comparable to N500 and N600 series using ASTM D8474-23 thermogravimetric analysis. Industry reports from Smithers (2023-2024) indicate 65% of tire makers cite rCB as the "best material to achieve sustainability goals," with typical passenger tire rCB performing close to N700 specifications and partial replacement possible for N300-N600 grades.

Conference presentations at the International Rubber Conference series, Recovered Carbon Black Asia Conference, and Tire Technology Expo demonstrate ongoing technical advancement and commercial implementation strategies.

Market transformation accelerates toward 2030

The global rCB market has grown from $259.3 million in 2024 to a projected $890.6 million in 2025, representing 35.12% compound annual growth. Current global production of approximately 20,000 tons annually will expand to over 250,000 tons by 2030 based on announced capacity additions. While current market penetration remains below 1% of global carbon black usage, long-term supply agreements and tire manufacturer sustainability commitments drive rapid adoption.

Bottom Line

The recovered carbon black industry has successfully demonstrated commercial production meeting ASTM D8474 specifications for N300-N600 grades through multiple industrial implementations. Advanced purification technologies, strategic partnerships between rCB producers and established carbon black manufacturers, and validation through tire manufacturer adoption confirm that specification-grade rCB represents a commercially viable sustainable alternative to virgin carbon black. The transition from pilot programs to industrial-scale production marks a fundamental shift in tire manufacturing sustainability.