Process gas decomposition reactor

• US 6,261,525 B1
• Filed: 05/17/2000
• Issued: 07/17/2001
• Est. Priority Date: 05/17/2000
• Status: Expired due to Fees

• Current Assignee: Greenx Incorporated
• Original Assignee: Greenx Incorporated
• Inventors: Minaee, Bruce
• Primary Examiner(s): Gorgos, Kathryn
• Assistant Examiner(s): TRAN, THAO T
• Application Number:
  US09/572,111
• Time in Patent Office: 426 Days
• Field of Search: 422/186, 219/678
• US Class Current: 422/186
• CPC Class Codes: B01J 19/126 Microwaves
• CPC Class Codes: B01J 2219/0871 Heating or cooling of the reactor
• CPC Class Codes: B01J 2219/0875 Gas
• CPC Class Codes: B01J 2219/0894 Processes carried out in the presence of a plasma
• CPC Class Codes: B01J 2219/1227 Reactors comprising tubes with open ends
• CPC Class Codes: B01J 2219/1296 Multiple sources
• CPC Class Codes: H05B 2206/046 Microwave drying of wood, ink, food, ceramic, sintering of ceramic, clothes, hair
• CPC Class Codes: H05B 6/782 wherein the material moved is food
• CPC Class Codes: H05B 6/802 for heating fluids methods of heating fluids in conventional microwave ovens H05B6/687
• CPC Class Codes: H05B 6/806 for laboratory use

Abstract

A process gas decomposition reactor featuring two intertwined helical coils surrounding a gas flow path. Each of the two coils is energized by a separate magnetron having an associated waveguide and an inductive structural element which couples the microwave energy into the coil. The magnetic flux lines from the coil serve to confine ions and electrons within the coil, causing collisions and hence ionization of gas entering a flow path through the coil. The gas, containing HFCs and PFCs is broken down by such collisions with ions and electrons within the gas plasma. The gas displaced at the end of the coil contains decomposition products from the HFCs and PFCs.

Claims

1. A process gas decomposition reactor comprising,

a reactor chamber having a gas inflow port spaced apart from a gas outflow port in a manner defining a gas flow path through a central region of the chamber,

a gas flow stream traversing the reactor chamber from the inflow port to the outflow port, the gas flow including process gas effluent and reaction gas,

first and second intertwined helical coils surrounding the gas flow path,

first and second spaced apart microwave frequency waveguides, exterior to the reaction chamber, each respectively joined to one of the first and second helical coils, and

first and second microwave energy oscillators feeding respective first and second waveguides, each waveguide feeding microwave energy to a respective one of the first and second helical coils, wherein reactive gases in the reaction chamber are heated to ionization by said energy for breakdown of the process gas effluent and recombination with the reaction gas.

2. The reactor of claim 1 wherein the reactor chamber is a tubular structure connected co-axially with process gas piping.

3. The apparatus of claim 2 wherein the waveguides are elongated ducts of rectangular cross section having linear axes transverse to the axis of the reaction chamber.

4. The apparatus of claim 1 wherein said helical coils are within the reactor chamber.

5. The apparatus of claim 4 wherein a tubular insulative jacket is disposed coaxially with said helical coils between the coils and the reactor chamber thereby insulating said coils.

6. The apparatus of claim 1 wherein the microwave energy oscillators are magnetron tubes.

7. The apparatus of claim 6 wherein each magnetron is in an enclosed housing supporting one of the waveguides.

8. The apparatus of claim 1 wherein the intertwined helical coils have the same diameter.

9. The apparatus of claim 1 wherein the process gas effluent includes perfluorinated and hydrofluorocarbon compounds.

10. The apparatus of claim 1 wherein the reaction gas is selected from oxygen, hydrogen and water vapor.

11. The apparatus of claim 1 further defined by first and second impedance matching transformers connecting the first and second waveguides with the first and second coils.

12. The apparatus of claim 11 wherein each of said transformers is annular with a central axis having a conductive post extending through the center of each annulus, each conductive post projecting into a waveguide and connected to an end of one of the helical coils thereby coupling energy from the waveguide into the helical coil.

13. The apparatus of claim 12 wherein a high voltage bar is disposed to contact each conductive post, wherein the conductive post can ignite a gas plasma.

14. The apparatus of claim 1 wherein said waveguides having tuning stubs establishing resonance in the waveguides with said oscillators, thereby stabilizing the frequency of the oscillators.

15. A process gas decomposition reactor comprising,

first and second coaxial intertwined helical coils insulated from each other and carrying current in opposite directions,

first and second spaced apart microwave oscillators,

first and second microwave waveguides electromagnetically connected between respective microwave oscillators and respective first and second helical coils, and

a gas flow path defined by a cylindrical housing having a flow axis coaxial with the helical coils.

16. The reactor of claim 15 further defined by first and second transformers each having a core and a winding, the core projecting into a microwave waveguide thereby receiving microwave energy and contacting one of said coils.

17. The reactor of claim 16 wherein the core of each transformer is electromagnetically connected to one of said coils.

18. The reactor of claim 15 wherein said first and second coils are intertwined.

19. The reactor of claim 15 wherein said first and second waveguides are parallel to each other.

20. The reactor of claim 15 wherein said housing comprises coaxial members including an insulative structure supporting the coils.

21. The reactor of claim 15 wherein the housing has ends formed as flanges with peripheral bolt holes.

22. A process gas decomposition reactor comprising,

a cylindrical reactor chamber having spaced apart mounting flanges for insertion in a process gas line, the chamber having an axis defining a gas flow path from one flange to the other,

first and second intertwined helical coils coaxially surrounding the gas flow path,

first and second housing containing microwave oscillators therein, the housings spaced apart a distance corresponding to the spacing of the mounting flanges for the chamber,

first and second microwave frequency waveguides spaced apart a distance corresponding to the spacing of the mounting flanges of the chamber, the microwave oscillators communicating electromagnetic energy to the waveguides from the microwave oscillators which, in turn communicate with each of the coils,

wherein the intertwined coils develop opposing magnetic flux lines parallel to the gas flow path causing electrons and ions spiraling about the flux lines to collide with gases traveling along the gas flow path thereby causing breakdown of said gases.

23. The apparatus of claim 22 wherein the microwave frequency waveguides are parallel to each other and perpendicular to the axis of the chamber.

24. The apparatus of claim 22 wherein the microwave frequency waveguides are atop the chamber and the microwave oscillator housings.