Environmental-friendly continuous process of manufacturing structure-controlled carbon black (CB) nanoparticles has been developed by the combination of advantages of alternative-current (AC) gliding arc plasma and direct-current (DC) arc discharge plasma. In this process, methane was first decomposed in the low temperature AC gliding arc plasma and then further thermally pyrolyzed in the DC arc discharge plasma area. CB was generated in the AC arc plasma area and then continued to grow or surface modified by DC arc plasma according to different arc positions, which was determined by the operating gas flow rate. The effects of AC arc and DC arc on the yield, size, morphology and structure of particles have been investigated. The connection of AC and DC plasma areas might cause totally different growth process of nanoparticles. Formation mechanism has been discussed based on series of physical characterizations to illustrate the different growth process. The essential properties of CB prepared by plasma have been compared with three kinds of CB purchased, and then all the CB nanoparticles have been blended with acrylonitrile-butadienestyrene/ethylene-propylene-diene monomer composites. Electrical conductivity and mechanical properties as well as the morphology of fracture surface of composites have been characterized. The results indicate that CB prepared from AC plasma process shows excellent mechanical reinforcement and CB from AC + DC plasma process owns outstanding electrical conductivity. (C) 2017 Published by Elsevier B.V.