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EP4605120A2 - Systèmes et procédés de modulation d'écoulements réactifs - Google Patents

Systèmes et procédés de modulation d'écoulements réactifs

Info

Publication number
EP4605120A2
EP4605120A2 EP23880839.8A EP23880839A EP4605120A2 EP 4605120 A2 EP4605120 A2 EP 4605120A2 EP 23880839 A EP23880839 A EP 23880839A EP 4605120 A2 EP4605120 A2 EP 4605120A2
Authority
EP
European Patent Office
Prior art keywords
generating section
thermal transfer
carbon particle
transfer gas
particle generating
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP23880839.8A
Other languages
German (de)
English (en)
Inventor
Mathew Leis
Markus Finkbeiner
Alexander Hoermann
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Monolith Materials Inc
Original Assignee
Monolith Materials Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Monolith Materials Inc filed Critical Monolith Materials Inc
Publication of EP4605120A2 publication Critical patent/EP4605120A2/fr
Pending legal-status Critical Current

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B32/00—Carbon; Compounds thereof
    • C01B32/05—Preparation or purification of carbon not covered by groups C01B32/15, C01B32/20, C01B32/25, C01B32/30
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J19/08—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor
    • B01J19/087—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor employing electric or magnetic energy
    • B01J19/088—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor employing electric or magnetic energy giving rise to electric discharges
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/08—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor
    • B01J2219/0869—Feeding or evacuating the reactor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/08—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor
    • B01J2219/0873—Materials to be treated
    • B01J2219/0875—Gas

Definitions

  • the present disclosure provides systems and methods for increasing time of flight of reactants within a reactor. Such systems and methods may reduce contact of reactants and reaction products with reactor walls to thereby reduce fouling of the reactor.
  • the present disclosure provides an apparatus for making carbon particles.
  • the apparatus may comprise a plasma generating section, a carbon particle generating section, and an obstacle disposed between the plasma generating section and the carbon particle generating section, wherein the obstacle is configured to contact, during use, a fluid flowing from the plasma generating section to the carbon particle generating section, thereby reducing angular momentum of the fluid.
  • the obstacle is configured to be static when contacting the fluid.
  • the apparatus comprises a throat section that is narrower than the plasma generating section or the carbon particle generating section.
  • the throat section is located between the plasma generating section and the carbon particle generating section.
  • the obstacle is located in the throat section.
  • the obstacle is located at or near an entrance to or an exit of the throat section.
  • the obstacle comprises a flat surface.
  • the obstacle comprises a curved surface.
  • the obstacle comprises a plate.
  • a surface of the obstacle is positioned perpendicular to a flow path of the fluid.
  • the present disclosure provides a method for making carbon particles.
  • the method may comprise providing an apparatus comprising (i) a plasma generating section, (ii) a carbon particle generating section, and (iii) an obstacle located between the plasma generating section and the carbon particle generating section; flowing a thermal transfer gas from the plasma generating section to the carbon particle generating section such that the thermal transfer gas contacts the obstacle, wherein contact of the thermal transfer gas with the obstacle reduces angular momentum of the thermal transfer gas; and in the carbon particle generating section, using the thermal transfer gas to generate the carbon particles.
  • the obstacle comprises a flat surface. In some embodiments, the obstacle comprises a curved surface. In some embodiments, the obstacle comprises a plate. In some embodiments, a surface of the obstacle is positioned perpendicular to a flow path of the thermal transfer gas. In some embodiments, the obstacle comprises a plurality of members. In some embodiments, a first member contacts a second member. In some embodiments, first and second members make contact at a center axis of the apparatus. In some embodiments, two or more members are interlocked with one another. In some embodiments, the members are interlocked with one another in a lattice. In some embodiments, members are oriented randomly with respect to one another.
  • the obstacle reduces angular momentum of the thermal transfer gas by at least about 50%. In some embodiments, the obstacle reduces angular momentum of the thermal transfer gas by at least about 90%. In some embodiments, a ratio of angular momentum of the thermal transfer gas to linear momentum of the thermal transfer gas is less than about 1.5 prior to the thermal transfer gas entering the carbon particle generating section. In some embodiments, a ratio of angular momentum of the thermal transfer gas to linear momentum of the thermal transfer gas is less than about 1 prior to the thermal transfer gas entering the carbon particle generating section. In some embodiments, the thermal transfer gas is contacted with a hydrocarbon feedstock in the carbon particle generating section.
  • the present disclosure provides a method for making carbon particles.
  • the method may comprise providing an apparatus comprising (i) a plasma generating section and (ii) a carbon particle generating section; flowing a thermal transfer gas from the plasma generating section to the carbon particle generating section such that angular momentum of the thermal transfer gas is reduced by at least about 50% prior to entering the carbon particle generating section; and in the carbon particle generating section, using the thermal transfer gas to generate the carbon particles.
  • the angular momentum of the thermal transfer gas is reduced by at least about 75%. In some embodiments, the angular momentum of the thermal transfer gas is reduced by at least about 90%. In some embodiments, the thermal transfer gas is contacted with a hydrocarbon feedstock in the carbon particle generating section. In embodiments, less than about 25%, 15%, 10%, or 5% of the hydrocarbon feedstock fouls the carbon particle generating section. In some embodiments, a ratio of angular momentum of the thermal transfer gas to linear momentum of the thermal transfer gas is less than about 1.5 prior to the thermal transfer gas entering the carbon particle generating section. In some embodiments, the method further comprises flowing the thermal transfer gas from the plasma generating section to the carbon particle generating section such that the thermal transfer gas contacts the obstacle prior to using the thermal transfer gas to generate the carbon particles.
  • the present disclosure provides a method for making carbon particles.
  • the method may comprise providing an apparatus comprising (i) a plasma generating section and (ii) a carbon particle generating section; flowing a thermal transfer gas from the plasma generating section to the carbon particle generating section, wherein a ratio of angular momentum of the thermal transfer gas to linear momentum of the thermal transfer gas is less than about 1.5 prior to the thermal transfer gas entering the carbon particle generating section; and in the carbon particle generating section, using the thermal transfer gas to generate the carbon particles.
  • the present disclosure provides a method for making carbon particles.
  • the method may comprise providing an apparatus comprising (i) a plasma generating section and (ii) a carbon particle generating section; flowing a thermal transfer gas with a first angular momentum from the plasma generating section to the carbon particle generating section, wherein the first angular momentum has a first magnitude and a first direction; contacting the thermal transfer gas with a fluid with a second angular momentum, wherein the second angular momentum has a second magnitude and a second direction, and wherein contact of the thermal transfer gas with the fluid reduces the first magnitude in the first direction of the first angular momentum; and in the carbon particle generating section, using the thermal transfer gas to generate the carbon particles.
  • the second direction of the second angular momentum opposes the first direction of the first angular momentum.
  • the first magnitude is greater than the second magnitude.
  • a ratio of the first magnitude to the second magnitude is greater than about 1.
  • a ratio of the first magnitude to the second magnitude is in a range of about 1 to about 5.
  • a ratio of the first magnitude to the second magnitude is in a range of about 1 to about 3.
  • a ratio of the first magnitude to the second magnitude is in a range of about 1 to about 2.
  • the fluid is a hydrocarbon feedstock. In some embodiments, contacting the thermal transfer gas with the hydrocarbon feedstock generates the carbon particles.
  • FIG. 1 shows a schematic representation of an example system with which one or more embodiments of the present disclosure may be disposed or used;
  • FIG. 2 shows an example graph of Swirl Number as a function of average reactor cleanout (fouling) as mass percent of total injected feedstock for various injector configurations without the benefit of the systems and methods of the present disclosure
  • FIG. 3 shows a schematic representation of flows before and after an obstacle according to one or more embodiments of the present disclosure.
  • FIG. 4 shows a side-view example obstacle configuration comprising intersecting plates, according to one or more embodiments of the present disclosure
  • a reaction chamber geometry may comprise or be a straight cylinder.
  • a reaction chamber geometry may comprise or be a cylinder with a narrowing portion or throat section.
  • the reactants may be mixed in the throat section prior to entering the main, larger diameter reaction chamber.
  • the characteristics of the reactant flow fields entering into the reaction chamber may control, alter, or maximize the Time of Flight of the reactants.
  • a reactor may include a plasma generating section and a carbon particle generating section.
  • a throat section may be disposed between the plasma generating section and carbon particle generating section. The throat section may be upstream of the carbon particle generating section.
  • High Swirl Number flows may have an effect of quickly mixing reactants along a plane perpendicular to the axis of the main flow to reduce Time of Flight.
  • high Swirl Number flows may shorten the axial recirculation bubble due to the higher angular acceleration of the fluid as compared to a reaction chamber without a rapid expansion zone. Shortening the axial recirculation bubble may aid in overcoming transverse pressure imbalance from conservation of axial momentum.
  • FIG. 3 shows a schematic representation of flows before and after an obstacle according to one or more embodiments of the present disclosure.
  • a reactor 300 may include an upstream section 305 containing electrodes (not shown) between which a gas may flow, where an electric arc will excite the gas into a plasma state. The electric arc may be controlled through use of a magnetic field which moves the arc in a circular fashion rapidly around the electrode tips.
  • the reactor may include a converging region 310 and a diverging region 315 defining a throat 320.
  • a hydrocarbon feedstock is then injected into the plasma gas through an injector (not shown).
  • Fluid properties of the electric arc plasma core may be so dissimilar from that of the bulk fluid that the arc can be considered a “bluff body.” Rapid rotation of the arc may impart swirl from the drag force between the arc core and the bulk fluid, similar to a rotating mechanical device.
  • the arc may rotate at a rate of greater than or equal to about 200 hertz (Hz), 300 Hz, 400 Hz, 500 Hz, 600 Hz, 800 Hz, 1000 Hz, 1200 Hz, 1400 Hz, 1600 Hz, 1800 Hz, 2000 Hz, 2200 Hz, 2400 Hz, 2600 Hz, 2800 Hz, 3000 Hz, 3200 Hz, 3400 Hz, or greater.
  • the arc may rotate at a rate in a range from about 200 Hz to 300 Hz, 200 Hz to 400 Hz, 200 Hz to 500 Hz, 200 Hz to 600 Hz, 200 Hz to 800 Hz, 200 Hz to 1000 Hz, 200 Hz to 1200 Hz, 200 Hz to 1400 Hz, 200 Hz to 1600 Hz, 200 Hz to 1800 Hz, 200 Hz to 2000 Hz, 200 Hz to 2200 Hz, 200 Hz to 2400 Hz, 200 Hz to 2600 Hz, 200 Hz to 2800 Hz, 200 Hz to 3000 Hz, 200 Hz to 3200 Hz, 200 Hz to 3400 Hz, 300 Hz to 400 Hz, 300 Hz to 500 Hz, 300 Hz to 600 Hz, 300 Hz to 800 Hz, 300 Hz to 1000 Hz, 300 Hz to 1200 Hz, 300 Hz to 1400 Hz, 300 Hz to 1600 Hz, 300 Hz to 1800 Hz, 300 Hz to 2000 Hz, 300 Hz to
  • the static mechanical device is disposed downstream of the throat and the feedstock is injected downstream of the static mechanical device.
  • the static mechanical device may be disposed in multiple sections of the reactor.
  • the static mechanical device may be disposed at least partially in the plasma generating section and the throat or at least partially in the throat and the carbon particle generating section.
  • a static mechanical device may comprise one or more obstacles.
  • FIGS. 4, 5, and 6 show various example obstacle configurations.
  • An obstacle may be a plate (e.g., flat or curved plate).
  • the plates of the static mechanical device may be coupled to or fixed to or in direct or indirect contact with walls of the reactor (e.g., walls of the plasma generating section, throat, or carbon particle generating section).
  • FIG. 4 shows a side-view example obstacle configuration 400 comprising intersecting plates, according to one or more embodiments of the present disclosure.
  • astatic mechanical device may comprise an obstacle 410 comprising one or more flat plates 420, 430.
  • the obstacle 410 may be disposed in or upstream of a throat section of the reactor.
  • the obstacle 410 may have a midpoint 415 that intersects with a center axis 440 of the reactor (e.g., plasma generating section, throat, or carbon particle generating section).
  • the static mechanical device obstacle 410 may comprise two flat plates 440 and 450 disposed perpendicular to or substantially perpendicular to one another to form a crosslike configuration.
  • the first dimension 450 of the plate may be equal to or substantially equal to a distance between interior walls of the reactor (e.g., plasma generating section, throat, carbon particle generating section, etc.).
  • the second dimension 460 of the flat plate may be the dimension parallel to the fluid flow path.
  • the plate may be disposed such that the fluid flow path flows along both sides of the plate parallel to the second dimension 460 dimension of the plate.
  • the second dimension 460 of the plate may be greater than or equal to about 200 millimeter (mm), 400 mm, 600 mm, 800 mm, 1000 mm, 1200 mm, 1400 mm, 1600 mm, 1800 mm, 2000 mm, 2200 mm, 2400 mm, or more.
  • the second dimension 460 of the plate may be less than or equal to about 2400 mm, 2200 mm, 2000 mm, 1800 mm, 1600 mm, 1400 mm, 1200 mm, 1000 mm, 800 mm, 600 mm, 400 mm, 200 mm, or less.
  • the second dimension 460 of the plate may be in a range from about 200 mm to 400 mm, 200 mm to 600 mm, 200 mm to 800 mm, 200 mm to 1000 mm, 200 mm to 1200 mm, 200 mm to 1400 mm, 200 mm to 1600 mm, 200 mm to 1800 mm, 200 mm to 2000 mm,
  • the static mechanical device may comprise an obstacle comprising a grid or array of interlocking plates.
  • the grid or array of plates may comprise a subset of plates disposed in a first direction and another subset of plates disposed in a second direction.
  • the first direction may be perpendicular to or substantially perpendicular to the second direction.
  • the grid or array of plates may be disposed perpendicular to an average direction of fluid flow.
  • FIG. 6 shows a side-view example obstacle configuration 600 comprising a series of plates, for example plate 610, according to one or more embodiments of the present disclosure.
  • a plate 610 may be coupled to a wall 620 of the reactor and another side of the plate 610 may extend radially into the fluid flow path, e.g., an average bulk fluid flow path aligned or substantially aligned in a direction parallel with a central axis 630.
  • a plate may have a first dimension 640 perpendicular to an average direction of fluid flow 630, a second dimension 650 parallel to an average direction of fluid flow 630, and a third dimension 660 (e.g., plate thickness) perpendicular to an average direction of fluid flow 550.
  • a plate fixed to the wall may have a first dimension 640 that may be greater than or equal to about 200 mm, 400 mm, 600 mm, 800 mm, 1000 mm, 1200 mm, 1400 mm, 1600 mm, 1800 mm, 2000 mm, 2200 mm, 2400 mm, or more.
  • the first dimension 640 may be less than or equal to about 2400 mm, 2200 mm, 2000 mm, 1800 mm, 1600 mm, 1400 mm, 1200 mm, 1000 mm, 800 mm, 600 mm, 400 mm, 200 mm, or less.
  • the first dimension 640 may be in a range from about 200 mm to 400 mm, 200 mm to 600 mm, 200 mm to 800 mm, 200 mm to 1000 mm, 200 mm to 1200 mm, 200 mm to 1400 mm, 200 mm to 1600 mm, 200 mm to 1800 mm, 200 mm to 2000 mm, 200 mm to 2200 mm, 200 mm to 2400 mm, 400 mm to 600 mm, 400 mm to 800 mm, 400 mm to 1000 mm, 400 mm to 1200 mm, 400 mm to 1400 mm, 400 mm to 1600 mm, 400 mm to 1800 mm, 400 mm to 2000 mm, 400 mm to 2200 mm, 400 mm to 2400 mm, 600 mm to 800 mm, 600 mm to 1000 mm, 600 mm to 1200 mm, 600 mm to 1400 mm, 600 mm to 1600 mm, 600 mm to 1800 mm, 400 mm to 2000 mm, 400 mm to 2200
  • the plate fixed to the wall may have a second dimension 650 that may be greater than or equal to about 200 mm, 300 mm, 400 mm, 600 mm, 800 mm, 1200 mm, 1600 mm, 2000 mm, 2400 mm, 2800 mm, 3200 mm, 3600 mm, or more.
  • the plate may have a second dimension 650 of less than or equal to about 3600 mm, 3200 mm, 2800 mm, 2400 mm, 2000 mm, 1600 mm, 1200 mm, 800 mm, 600 mm, 400 mm, 300 mm, 200 mm, or less.
  • the plate may have a third dimension 660 in a range from about 1 mm to 5 mm, 1 mm to 10 mm, 1 mm to 20 mm, 1 mm to 40 mm, 1 mm to 60 mm, 1 mm to 80 mm, 1 mm to 100 mm, 5 mm to 10 mm, 5 mm to 20 mm, 5 mm to 40 mm, 5 mm to 60 mm, 5 mm to 80 mm, 5 mm to 100 mm, 10 mm to 20 mm, 10 mm to 40 mm, 10 mm to 60 mm, 10 mm to 80 mm, 10 mm to 100 mm, 20 mm to 40 mm, 20 mm to 60 mm, 20 mm to 80 mm, 20 mm to 100 mm, 40 mm to 60 mm, 40 mm to 80 mm, 40 mm to 100 mm, 60 mm to 80 mm, 60 mm to 100 mm, or 80 mm to 100 mm.
  • FIGS. 8A - 8D show example top-view obstacle configurations, each according to one or more embodiments of the present disclosure, as described elsewhere herein.
  • FIG. 8A shows an example obstacle configuration comprising three radially intersecting plates 810.
  • FIG. 8B shows an example obstacle configuration comprising three non-intersecting plates 820.
  • FIG. 8C shows an example obstacle configuration comprising a grid of three interlocking plates 830.
  • FIG. 8D shows an example obstacle configuration comprising a grid of six interlocking plates 840.
  • a static mechanical device may further comprise one or more obstacles comprising a tight latticework of solid material.
  • FIG. 9 shows an example latticework structure according to one or more embodiments of the present disclosure.
  • the latticework may comprise a three- dimensional structure with a series of patterned pores.
  • the series of patterned pores may be a random series of pores or an organized pattern of pores.
  • the latticework of solid material may provide drag on the flow and reduce bulk fluid flow momentum and velocity to momentum and velocity driven by the axial pressure gradient.
  • the latticework of solid material may comprise a structure similar to an atomic metallic “lattice.”
  • the latticework of solid material may comprise a plurality of pores that permit transport of the fluid therethrough.
  • the latticework comprises a molecular sieve.
  • the latticework comprises a sponge diffuser.
  • Pores of the plurality of pores may have an average diameter of greater than or equal to about 0.5 mm, 1 mm, 2 mm, 3 mm, 4 mm, 5 mm, 10 mm, 20 mm, 30 mm, 40 mm, 50 mm, 60 mm, or more.
  • Pores of the plurality of pores may have an average diameter of less than or equal to about 60 mm, 50 mm, 40 mm, 30 mm, 20 mm, 10 mm, 5 mm, 4 mm, 3 mm, 2mm, 1 mm, 0.5 mm, or less.
  • Pores of the plurality of pores may have an average diameter in a range from about 0.5 mm to 1 mm, 0.5 mm to 2 mm, 0.5 mm to 3 mm, 0.5 mm to 4 mm, 0.5 mm to 5 mm, 0.5 mm to 10 mm, 0.5 mm to 20 mm, 0.5 mm to 30 mm, 0.5 mm to 40 mm, 0.5 mm to 50 mm, 0.5 mm to 60 mm, 1 mm to 2 mm, 1 mm to 3 mm, 1 mm to 4 mm, 1 mm to 5 mm, 1 mm to 10 mm, 1 mm to 20 mm, 1 mm to 30 mm, 1 mm to 40 mm, 1 mm to 50 mm, 1 mm to 60 mm, 2 mm to 3 mm, 2 mm to 4 mm, 2 mm to 5 mm, 2 mm to 10 mm, 2 mm to 20 mm, 2 mm to 30 mm, 2 mm to 40 mm
  • the pore size (e.g., pore diameter) may be greater than or equal to about 5 mm.
  • the porous structure may be visible to a human eye.
  • the pores of the latticework of solid material may be constant or may vary in size across the latticework of solid material. The size of the pores may vary by less than or equal to about 60%, 50%, 40%, 30%, 20%, 10%, or less.
  • the latticework may be a randomly oriented lattice (e.g., similar to a natural sponge) or an ordered lattice.
  • the latticework may be formed of solid carbon, carbon composite, ceramic, refractory metals, carbide variations of refractory metals, or any combination thereof.
  • Swirl Number of a bulk fluid flow may be reduced through introduction of a secondary fluid to the bulk fluid flow.
  • the secondary fluid may generate or impart a shear force in the bulk flow which may reduce or dissipate the total angular momentum of the combined fluids and reduce swirl.
  • the secondary fluid may have an angular momentum with a direction that opposes a direction of the angular momentum of the bulk fluid.
  • An angle between the angular momentum of the secondary fluid and the bulk fluid may be greater than or equal to about 20 degrees (°), 30°, 40°, 50°, 60°, 70°, 80°, 90°, or more.
  • An angle between the angular momentum of the secondary fluid and the bulk fluid may be less than or equal to about 90°, 80°, 70°, 60°, 50°, 40°, 30°, 20°, or less.
  • An angle between the angular momentum of the secondary fluid and the bulk fluid may be in a range from about 20° to 30°, 20° to 40°, 20° to 50°, 20° to 60°, 20° to 70°, 20° to 80°, 20° to 90°, 30° to 40°, 30° to 50°, 30° to 60°, 30° to 70°, 30° to 80°, 30° to 90°, 40° to 50°, 40° to 60°, 40° to 70°, 40° to 80°, 40° to 90°, 50° to 60°, 50° to 70°, 50° to 80°, 50° to 90°, 60° to 70°, 60° to 80°, 60° to 90°, 70° to 80°, 70° to 90°, or 80° to 90°.
  • the secondary fluid may be the same fluid as the bulk fluid or a different fluid.
  • the secondary fluid may comprise hydrogen, a hydrocarbon (e.g., methane, ethane, propane, etc.) or hydrocarbon derivative, or any combination thereof.
  • the secondary fluid may be an inert gas such as (for example) argon, nitrogen, carbon monoxide, carbon dioxide, or any combination thereof.
  • the secondary fluid comprises reactant or feedstock. Contacting the bulk fluid with the secondary fluid may reduce the angular momentum of the bulk fluid by at least about 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, or more as compared to the bulk fluid not contacted with the secondary fluid.
  • the angular momentum of the bulk fluid may be reduced prior to the bulk fluid entering the carbon particle generating section of the reactor.
  • contacting the bulk fluid with the secondary fluid may reduce the angular momentum of the bulk fluid by at least about 50%.
  • contacting the bulk fluid with the secondary fluid may reduce the angular momentum of the bulk fluid by at least about 75%.
  • contacting the bulk fluid with the secondary fluid may reduce the angular momentum of the bulk fluid by at least about 90%.
  • Contacting the bulk fluid with the secondary fluid may provide a fluid with a ratio of angular momentum to linear momentum that is less than or equal to about 2, 1.5, 1.25, 1, or less.
  • contacting the bulk fluid with the secondary fluid may provide a fluid with a ratio of angular momentum to linear momentum that is less than or equal to about 1.5. In another example, contacting the bulk fluid with the secondary fluid may provide a fluid with a ratio of angular momentum to linear momentum that is less than or equal to about 1.25. In another example, contacting the bulk fluid with the secondary fluid may provide a fluid with a ratio of angular momentum to linear momentum that is less than or equal to about 1.
  • the reactor may include a bulk fluid that rotates 1040 as it progresses down the length of the reactor (not shown).
  • the bulk fluid may rotate 1040 clockwise or counterclockwise.
  • the reactor may include an internal wall 1020 with one or more secondary fluid injectors 1000 (FIG. 10A) or 1030 (FIG. 10B) that are disposed through the wall 1020.
  • the injectors 1000 may be flush mounted (e.g., as shown in FIG. 10A), or the injectors 1030 may protrude into the bulk fluid flow (e.g., as shown in FIG. 10B).
  • the secondary fluid injectors 1000 or 1030 may generate a secondary fluid jet 1050 directed in opposition to the bulk fluid rotation 1040.
  • An injector 1000 or 1030 may inject the secondary fluid 1050 into the rotating bulk fluid 1040 at an angle of greater than or equal to about 20 degrees (°), 30°, 40°, 50°, 60°, 70°, 80°, 90°, or more from the reactor internal wall 1020.
  • An injector 1000 or 1030 may inject the secondary fluid 1050 into the rotating bulk fluid 1040 at an angle of less than or equal to about 90°, 80°, 70°, 60°, 50°, 40°, 30°, 20°, or less from the reactor wall 702.
  • the secondary fluid 1040 may comprise reactant or feedstock, and a set of injectors (e.g., nozzles) 1000 or 1030 may inject the secondary fluid into the rotating main bulk flow 1050.
  • the set of injectors 1000 or 1030 may comprise at least 2, 3, 4, 5, 6, 8, 10, or more injectors (e.g., nozzles).
  • the set of injectors comprises at least three nozzles spaced equidistantly around the circumference of the reactor 1010.
  • the set of injectors 1000 or 1030 may be positioned such that the angular momentum of the secondary fluid 1040 opposes the angular momentum of the rotating bulk fluid 1050 to minimize heat loss while providing balanced flow control.
  • the systems and methods described herein may reduce an amount of hydrocarbon feedstock that fouls the reactor (e.g., carbon particle generating section of the reactor). Reducing angular momentum of the bulk fluid flow may reduce an amount of hydrocarbon feedstock converted to fouling material to less than or equal to about 40%, 30%, 25%, 15%, 10%, 5%, or less of the hydrocarbon feedstock injected into the reactor (e.g., carbon particle generating section). In an example, reducing angular momentum of the bulk fluid flow reduces an amount of hydrocarbon feedstock converted to fouling material to less than or equal to about 25% of the hydrocarbon feedstock injected into the reactor (e.g., carbon particle generating section).
  • the present disclosure provides systems and methods for effecting chemical changes. Effecting such chemical changes may include, for example, making or generating carbonaceous material, hydrogen, or a combination thereof using the systems and methods described herein.
  • a carbonaceous material may be solid.
  • a carbonaceous material may comprise or be, for example, carbon particles, a carbon-containing compound, or a combination thereof.
  • a carbonaceous material may include, for example, carbon black.
  • the systems (e.g., apparatuses) and methods of the present disclosure, and processes implemented with the aid of the systems and methods herein, may allow continuous production of, for example, carbonaceous material, hydrogen, or a combination thereof.
  • the processes may include converting a feedstock (e.g., one or more hydrocarbons, hydrocarbon derivatives, or combination thereof).
  • the systems and methods described herein may include heating one or more hydrocarbons rapidly to form, for example, carbonaceous material, hydrogen, or combination thereof.
  • one or more hydrocarbons may be heated rapidly to form carbon particles, hydrogen, or combination thereof.
  • Hydrogen may in some cases refer to majority hydrogen (H2).
  • H2 majority hydrogen
  • some portion of this hydrogen may also contain methane (e.g., unspent methane) or various other hydrocarbons (e.g., ethane, propane, ethylene, acetylene, benzene, toluene, polycyclic aromatic hydrocarbons (PAHs) such as naphthalene, etc.).
  • methane e.g., unspent methane
  • various other hydrocarbons e.g., ethane, propane, ethylene, acetylene, benzene, toluene, polycyclic aromatic hydrocarbons (PAHs) such as naphthalene, etc.
  • the temperature of a reactor can be increased to selectively produce hydrogen, carbon particles, or combinations thereof.
  • the temperature of a reactor can be tuned to increase or decrease the surface area of carbon particles.
  • Increasing reactor temperatures can increase the kinetic rates of feedstock decomposition as well as the intermediate operations which can produce formation of carbon particles and hydrogen.
  • Increasing reactor temperatures also can increase the rate of carbon particle aging and can reduce reactor wall fouling. This may be due to reducing the time before the carbon particles are chemically inert.
  • the systems described herein may comprise plasma generators energized by a DC or AC power source.
  • the gas or gas mixture may be supplied directly into a zone in which an electric discharge produced by the DC or AC power source is sustained.
  • the plasma may have a composition as described elsewhere herein (e.g., in relation to composition of the one or more gases).
  • the plasma may be generated using electric arc heating.
  • the plasma may be generated using inductive heating.
  • the plasma may be generated using DC electrodes.
  • the plasma may be generated using AC electrodes.
  • a plurality (e.g., 3 or more) of AC electrodes may be used (e.g., with the advantage of more efficient energy consumption as well as reduced heat load at the electrode surface).
  • the material generated by the electric arc may be plasma in a range as defined by any two of the preceding percentage values.
  • material generated by the electric arc may be in a range between about 5% and about 30% plasma.
  • the one or more gases may be heated by Joule heating (e.g., resistive heating, induction heating, or a combination thereof).
  • the one or more gases may be heated by Joule heating and by an electric arc (e.g., downstream of the Joule heating).
  • the one or more gases may be heated by heat exchange, by Joule heating, by an electric arc, or any combination thereof.
  • the one or more gases may be heated by heat exchange, by Joule heating, by combustion, or any combination thereof.
  • At least one of the one or more gases may comprise a hydrocarbon.
  • the one or more gases may include a feedstock.
  • the one or more gases may include the feedstock alone or in combination with other gases (which other gases, alone or in combination with other gases which are not heated, may be referred to herein as “process gases”).
  • the one or more gases may include the feedstock and at least one process gas. Individual gases among the one or more gases may be provided (e.g., to a reactor) separately or in various combinations. At least a subset of the one or more gases may be pre-heated.
  • the feedstock e.g., the hydrocarbon or the hydrocarbon feedstock
  • the process may include heating at least a subset of the one or more gases (e.g., the feedstock) at suitable reaction conditions (e.g., in the reactor).
  • the heating may effect removal of hydrogen from the feedstock.
  • the feedstock e.g., one or more hydrocarbons
  • the feedstock may be cracked by the heating such that at least about 80% by moles of the hydrogen originally chemically attached through covalent bonds to a hydrocarbon may become homoatomically bonded as diatomic hydrogen.
  • Homoatomically bonded may refer to the bond being between two atoms that are the same (e.g., as in diatomic hydrogen (H2)).
  • C-H may be a heteroatomic bond.
  • a hydrocarbon may go from heteroatomically bonded C-H to homoatomically bonded H-H (e.g., as in diatomic hydrogen (H2)) and C-C (e.g., as in solid carbonaceous material).
  • Reaction products may include an effluent stream of, for example, gases and solids that exit the reactor.
  • the effluent stream comprising the reaction products may be cooled.
  • the reaction products may be at least partially separated (e.g., after cooling).
  • solid carbonaceous material may be at least partially separated from the other (e.g., gaseous) reaction products.
  • the hot gas may be generated by heating at least a subset of one or more gases (e.g., a feedstock alone or in combination with at least one process gas) using the AC electrodes, the DC electrodes, or the resistive or inductive heater.
  • the heating may include directly heating a feedstock (e.g., a hydrocarbon feedstock).
  • the feedstock e.g., hydrocarbon feedstock
  • the thermal generator e.g., at a pressure described elsewhere herein.
  • the feedstock e.g., hydrocarbon feedstock
  • the reactor (or at least a portion thereof, such as, for example, at least a portion of an inner wall of the reactor) may comprise a liner (e.g., a refractory liner).
  • a feedstock e.g., hydrocarbon feedstock
  • the feedstock e.g., hydrocarbon feedstock
  • a process gas provided with the feedstock or in parallel with the feedstock may be heated.
  • a process gas may modify the environment or atmosphere in or around at least a portion of the reactor, the thermal generator, inlet port(s), or injector(s), purge at least a portion of the reactor, the thermal generator, inlet port(s) or injector(s), or any combination thereof.
  • an inlet port, an array of inlet ports or a plenum e.g., at the top of a reactor
  • the one or more gases may comprise substantially only the hydrocarbon (e.g., the feedstock).
  • the one or more gases that are heated with electrical energy may comprise the feedstock, and either no process gases, or process gas(es) at purge level(s) or some process gas(es) added with the feedstock (e.g., the one or more gases that are heated with electrical energy may comprise the feedstock and process gas(es) at purge level(s)).
  • the electrodes may be at least about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24 or more feet in length.
  • the electrodes may be at most about 24, 23, 22, 21, 20, 19, 18, 17, 16, 15, 14, 13, 12, 11, 10, 9, 8, 7, 6, 5, 4, 3, 2, 1, or less feet in length.
  • the distance between the center point of the electrode arc and the wall of the reactor may be at least about 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1,
  • the distance between the center point of the electrode arc and the wall of the reactor may be at most about 4, 3.9, 3.8, 3.7, 3.6, 3.5, 3.4, 3.3,
  • the gap between the electrodes may be, for example, less than or equal to about 40 millimeters (mm), 39 mm, 38 mm, 37 mm, 36 mm, 35 mm, 34 mm, 33 mm, 32 mm, 31 mm, 30 mm, 29 mm, 28 mm, 27 mm, 26 mm, 25 mm, 24 mm, 23 mm, 22 mm, 21 mm, 20 mm, 19 mm, 18 mm, 17 mm, 16 mm, 15 mm, 14 mm, 13 mm, 12 mm, 11 mm, 10 mm, 9 mm, 8 mm, 7 mm, 6 mm, 5 mm, 4 mm, 3 mm, 2 mm, or 1 mm.
  • mm millimeters
  • the electrodes, injectors, or both may possess an angle of inclination (e.g., an angle between the long axis of the electrode or injector and the long axis of the reactor) of at least about 0, 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, or more degrees.
  • the electrodes or the injectors may possess an angle of inclination of at most about 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 20, 15, 10, 5, 0, or less degrees.
  • the electrodes or the injectors may possess an angle of inclination in a range as defined by any two of the preceding values.
  • At least a portion of a reactor in accordance with the present disclosure may comprise one or more of the aforementioned materials (e.g., the reactor may be refractory-lined).
  • the reactor e.g., wall or liner of the reactor
  • the reactor may comprise one or more sections comprising different materials.
  • the refractory liner may comprise one or more sections comprising different refractory materials, such as, for example, a section that may be too hot for a given refractory material and another section comprising the given (e.g., standard) refractory material.
  • the process gas may comprise, for example, oxygen, nitrogen (e.g., up to about 30% by volume), argon (Ar) (e.g., up to about 30% by volume), helium, air, hydrogen (e.g., greater than or equal to about 50%, 60%, 70%, 80% and 90%, up to about 100% by volume), carbon monoxide (e.g., at least about 1 ppm by volume and up to about 30%), water, hydrocarbon (e.g., methane, ethane, unsaturated, benzene and toluene or similar monoaromatic hydrocarbon, polycyclic aromatic hydrocarbon such as anthracene and its derivatives, naphthalene and its derivatives, methyl naphthalene, methyl anthracene, coronene, pyrene, chrysene, fluorene and the like, or any hydrocarbon described herein in relation to the feedstock; for example, at least about 1 ppm by volume and up to about 30% methane
  • the feedstock may be provided at a pressure in a range of about 30 to about 35 bar, and may be metered down to a pressure in a range of about 5 to about 15 bar.
  • an inlet pressure of the reactor and an outlet pressure of the reactor may be different.
  • the outlet pressure of the reactor may be a value selected from the preceding list that is less than an inlet pressure selected from the preceding list.
  • a reactor with an about 15 bar inlet pressure may have an about 14 bar outlet pressure.
  • the inlet pressure may be about 4 bar and the outlet pressure may be about 2 bar.
  • the inlet pressure may be about 35 bar and the outlet pressure may be about 30 bar.
  • the pressure drop across the reactor can aid in the movement of gases or carbon particles through the reactor.
  • the one or more electrodes may comprise one or more alternating current (AC) electrodes.
  • AC electrodes may be electrodes configured to operate under AC conditions.
  • AC electrodes can be electronically coupled to an AC power supply and generate a plasma when AC current is flowed through the AC electrodes.
  • the one or more electrodes may comprise one or more direct current (DC) electrodes.
  • DC electrodes may be configured to operate under DC conditions (e.g., when operatively coupled to a DC power supply).
  • the reactor may be operated at a pressure less than or equal to at most about 100 bar, 90 bar, 80 bar, 75 bar, 70 bar, 65 bar, 60 bar, 55 bar, 50 bar, 45 bar, 40 bar, 35 bar, 30 bar, 29 bar, 28 bar, 27 bar, 26 bar, 25 bar,
  • the CPU 1105 can be part of a circuit, such as an integrated circuit.
  • a circuit such as an integrated circuit.
  • One or more other components of the system 1101 can be included in the circuit.
  • the circuit is an application specific integrated circuit (ASIC).
  • a reactor is operated for a time period of months in a stable mechanical configuration.
  • the reactor may comprise two chambers, a plasma generating section and a carbon particle generating section, separated by a throat section.
  • the reactor may further include a flow straightening device (also referred to herein as a “flow straightener”) of the present disclosure disposed downstream of the throat section.
  • a flow straightening device also referred to herein as a “flow straightener”
  • the flow straightener utilized was of a similar obstacle configuration to those shown in FIGS. 4 and 7A.

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  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Health & Medical Sciences (AREA)
  • General Health & Medical Sciences (AREA)
  • Toxicology (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Physical Or Chemical Processes And Apparatus (AREA)
  • Carbon And Carbon Compounds (AREA)

Abstract

La présente invention concerne des systèmes et des procédés de modulation d'écoulements réactifs. Les systèmes décrits ici peuvent comprendre une section de génération de plasma, une section de génération de particules de carbone et un obstacle situé entre la section de génération de plasma et la section de génération de particules de carbone. L'obstacle peut être conçu pour entrer en contact avec un fluide s'écoulant de la section de génération de plasma à la section de génération de carbone et ainsi réduire le moment angulaire du fluide. L'obstacle peut modifier l'écoulement de fluide de manière à ce qu'un rapport entre le moment angulaire et le moment linéaire du gaz soit inférieur à 1,5 environ. L'obstacle permet de réduire l'encrassement du système comparé à un système sans obstacle. Les procédés décrits ici permettent d'utiliser les systèmes décrits ici pour moduler des écoulements réactionnels.
EP23880839.8A 2022-10-21 2023-10-20 Systèmes et procédés de modulation d'écoulements réactifs Pending EP4605120A2 (fr)

Applications Claiming Priority (3)

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US202263418357P 2022-10-21 2022-10-21
US202363468989P 2023-05-25 2023-05-25
PCT/US2023/077402 WO2024086782A2 (fr) 2022-10-21 2023-10-20 Systèmes et procédés de modulation d'écoulements réactifs

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JP (1) JP2025536971A (fr)
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CA (1) CA3271383A1 (fr)
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WO (1) WO2024086782A2 (fr)

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ES2954251T3 (es) 2014-01-31 2023-11-21 Monolith Mat Inc Antorcha de plasma con electrodos de grafito
KR102705340B1 (ko) 2015-02-03 2024-09-09 모놀리스 머티어리얼스 인코포레이티드 카본 블랙 생성 시스템
MX2018001259A (es) 2015-07-29 2018-04-20 Monolith Mat Inc Aparato y método de diseño de energía eléctrica para soplete de plasma cc.
MX2018001612A (es) 2015-08-07 2018-05-28 Monolith Mat Inc Método para la fabricación de negro de humo.
MX2018002943A (es) 2015-09-09 2018-09-28 Monolith Mat Inc Grafeno circular de pocas capas.

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US4217132A (en) * 1977-09-27 1980-08-12 Trw Inc. Method for in-flight combustion of carbonaceous fuels
US4693808A (en) * 1986-06-16 1987-09-15 Shell Oil Company Downflow fluidized catalytic cranking reactor process and apparatus with quick catalyst separation means in the bottom thereof
US7622693B2 (en) * 2001-07-16 2009-11-24 Foret Plasma Labs, Llc Plasma whirl reactor apparatus and methods of use
KR20090040406A (ko) * 2006-05-05 2009-04-24 플라스코에너지 아이피 홀딩스, 에스.엘., 빌바오, 샤프하우젠 브랜치 플라즈마 토치 가열을 사용하는 가스 재구성 시스템
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JP2025536971A (ja) 2025-11-12
WO2024086782A2 (fr) 2024-04-25
MX2025004624A (es) 2025-08-01
KR20250130289A (ko) 2025-09-01
WO2024086782A3 (fr) 2024-05-23

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