Use of a chemically reactive plasma for thermal-chemical processes
First Claim
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1. A method for maximizing an operating efficiency of an inductively coupled plasma (ICP) torch in which a plasma is generated, comprising the steps of:
- (a) specifying a gaseous fluid used to generate the plasma;
(b) as a function of the gaseous fluid used to generate the plasma, modeling the ICP torch to determine an optimal flow rate of the gaseous fluid and an optimal power level for energizing an induction coil of the ICP torch to generate the plasma; and
(c) operating the ICP torch with the optimal flow rate of the gaseous fluid, and with the optimal power level applied to energize the induction coil of the ICP torch, so that the efficiency of the ICP torch is substantially maximized.
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Abstract
A method for optimizing the efficiency of an inductively coupled plasma (ICP) torch by varying at least one of a plasma gas flow rate and a power level applied to energize the ICP torch, and method and apparatus for efficiently using a CO2 feed as both a reactant and for generating a thermal plasma to produce high value chemical feed stocks, such as a synthesis gas or carbon monoxide from low value feedstocks, such as methane or carbon.
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Citations
56 Claims
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1. A method for maximizing an operating efficiency of an inductively coupled plasma (ICP) torch in which a plasma is generated, comprising the steps of:
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(a) specifying a gaseous fluid used to generate the plasma; (b) as a function of the gaseous fluid used to generate the plasma, modeling the ICP torch to determine an optimal flow rate of the gaseous fluid and an optimal power level for energizing an induction coil of the ICP torch to generate the plasma; and (c) operating the ICP torch with the optimal flow rate of the gaseous fluid, and with the optimal power level applied to energize the induction coil of the ICP torch, so that the efficiency of the ICP torch is substantially maximized. - View Dependent Claims (2, 3, 4, 5, 6)
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7. A method for maximizing a product yield from a reaction vessel in which plasma gas from an inductively coupled plasma (ICP) torch reacts with a feedstock material in a reaction vessel, comprising the steps of:
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(a) specifying a gaseous fluid used to generate the plasma; (b) specifying a feedstock material; (c) as a function of a gaseous fluid used to generate the plasma, modeling the ICP torch to determine an optimal flow rate of the gaseous fluid used to generate the plasma and an optimal power level for energizing an induction coil of the ICP torch to generate the plasma; (d) operating the ICP torch with the optimal flow rate of the gaseous fluid and with the optimal power level applied to the induction coil of the ICP torch, so that the efficiency of the ICP torch is substantially maximized; and (e) adjusting the flow rate of the feedstock material, so that the product yield is substantially maximized. - View Dependent Claims (8, 9, 10, 11)
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12. A method for using CO2 both as a chemical reactant and for producing a thermal plasma to convert a feedstock material into a tailored gas composition within a reaction vessel, comprising the steps of:
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(a) providing a plasma generator, a variable CO2 gas supply system, a variable power supply connected to energize the plasma generator, a reaction vessel having an inlet adapted to receive a thermal plasma produced by said plasma generator and an outlet from which a product is output, and a variable feedstock supply system adapted to inject said feedstock material into said reaction vessel; (b) supplying CO2 to the plasma generator so that the plasma generator ionizes the CO2 to produce ionized CO2 that is the thermal plasma; (c) injecting the ionized CO2 from the plasma generator into the reaction vessel to simultaneously provide heat and a reactant; and (d) injecting the feedstock material into the reaction vessel to react with the ionized CO2, said ionized CO2 thus serving both as the thermal plasma, which is a reaction heat source, and as a chemical reactant for processing the feedstock material. - View Dependent Claims (13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36)
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37. Apparatus for converting a feedstock material into a tailored gas composition using CO2 as both a chemical reactant with the feedstock material, and for producing a thermal plasma in a reaction vessel, comprising:
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(a) a plasma generator capable of sustained production of a plasma, said plasma generator having an inlet port, an outlet port, and a heat sink that maintains an internal surface of the plasma generator below a predetermined maximum temperature, said plasma generator being connected to a variable power supply to energize the plasma generator; (b) a variable CO2 gas supply system that provides CO2 gas to be ionized by the plasma generator, producing ionized CO2 for the thermal plasma; (c) a reaction vessel coupled to the outlet port of the plasma generator to receive the thermal plasma, said reaction vessel containing at least one injection port through which a feedstock material is injected into the thermal plasma, said at least one injection port being connected to a variable feedstock supply system; and (d) an outlet port from said reaction vessel adapted to convey a high temperature product of a reaction between the feedstock material and the ionized CO2 from the reaction vessel, said product being produced by a reaction between the ionized CO2 and the feedstock material using energy from the thermal plasma to promote the reaction. - View Dependent Claims (38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56)
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Specification