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US20170034898A1 - Dc plasma torch electrical power design method and apparatus - Google Patents

Dc plasma torch electrical power design method and apparatus Download PDF

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Publication number
US20170034898A1
US20170034898A1 US15/221,088 US201615221088A US2017034898A1 US 20170034898 A1 US20170034898 A1 US 20170034898A1 US 201615221088 A US201615221088 A US 201615221088A US 2017034898 A1 US2017034898 A1 US 2017034898A1
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US
United States
Prior art keywords
power supply
torch
voltage
current
arc
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.)
Abandoned
Application number
US15/221,088
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English (en)
Inventor
John Jared MOSS
Brian T. NOEL
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
Priority to US15/221,088 priority Critical patent/US20170034898A1/en
Publication of US20170034898A1 publication Critical patent/US20170034898A1/en
Assigned to Monolith Materials, Inc. reassignment Monolith Materials, Inc. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: NOEL, BRIAN T., MOSS, John Jared
Priority to US16/892,199 priority patent/US11665808B2/en
Priority to US18/137,918 priority patent/US12250764B2/en
Assigned to Monolith Materials, Inc. reassignment Monolith Materials, Inc. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: MOSS, John Jared, NOEL, BRIAN T.
Abandoned legal-status Critical Current

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01T—SPARK GAPS; OVERVOLTAGE ARRESTERS USING SPARK GAPS; SPARKING PLUGS; CORONA DEVICES; GENERATING IONS TO BE INTRODUCED INTO NON-ENCLOSED GASES
    • H01T13/00—Sparking plugs
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05H—PLASMA TECHNIQUE; PRODUCTION OF ACCELERATED ELECTRICALLY-CHARGED PARTICLES OR OF NEUTRONS; PRODUCTION OR ACCELERATION OF NEUTRAL MOLECULAR OR ATOMIC BEAMS
    • H05H1/00—Generating plasma; Handling plasma
    • H05H1/24—Generating plasma
    • H05H1/26—Plasma torches
    • H05H1/32—Plasma torches using an arc
    • H05H1/34—Details, e.g. electrodes, nozzles
    • H05H1/36—Circuit arrangements
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05H—PLASMA TECHNIQUE; PRODUCTION OF ACCELERATED ELECTRICALLY-CHARGED PARTICLES OR OF NEUTRONS; PRODUCTION OR ACCELERATION OF NEUTRAL MOLECULAR OR ATOMIC BEAMS
    • H05H1/00—Generating plasma; Handling plasma
    • H05H1/24—Generating plasma
    • H05H1/26—Plasma torches
    • H05H1/32—Plasma torches using an arc
    • H05H1/34—Details, e.g. electrodes, nozzles
    • H05H1/3431—Coaxial cylindrical electrodes
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05H—PLASMA TECHNIQUE; PRODUCTION OF ACCELERATED ELECTRICALLY-CHARGED PARTICLES OR OF NEUTRONS; PRODUCTION OR ACCELERATION OF NEUTRAL MOLECULAR OR ATOMIC BEAMS
    • H05H1/00—Generating plasma; Handling plasma
    • H05H1/24—Generating plasma
    • H05H1/47—Generating plasma using corona discharges
    • H05H1/473—Cylindrical electrodes, e.g. rotary drums
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05H—PLASMA TECHNIQUE; PRODUCTION OF ACCELERATED ELECTRICALLY-CHARGED PARTICLES OR OF NEUTRONS; PRODUCTION OR ACCELERATION OF NEUTRAL MOLECULAR OR ATOMIC BEAMS
    • H05H1/00—Generating plasma; Handling plasma
    • H05H1/24—Generating plasma
    • H05H1/2406—Generating plasma using dielectric barrier discharges, i.e. with a dielectric interposed between the electrodes
    • H05H1/2443—Generating plasma using dielectric barrier discharges, i.e. with a dielectric interposed between the electrodes the plasma fluid flowing through a dielectric tube
    • H05H2001/3431—

Definitions

  • a method of operating a DC plasma arc torch is described using plasma forming gas and an operating voltage power supply, where the power supply is at least two times the average operating voltage used, resulting in more stable operation of the torch including reduced voltage fluctuations and substantially no extinguishing of the arc.
  • Additional embodiments include: the method described above where the torch is operated in a power regulating mode where the power supply is operated at a given power setpoint, and the power supply adjusts both the output voltage and the current in order to keep the output power at the setpoint; the method described above where the torch is operated with a current setpoint at which the power supply switches into current regulated mode to keep the arc from extinguishing, and then raises the current setpoint and switches back to power regulated mode once the current is high enough to keep the arc from extinguishing, resulting in substantial elimination of voltage fluctuations and substantial elimination of the arc extinguishing; the method described above where the torch includes concentric cylinder electrodes; the method described above where the power supply has the capability of igniting the torch at a pulse voltage of at least 20 kilovolts; the method described above where the electrodes comprise graphite; the method described above where the plasma forming gas is hydrogen.
  • An apparatus comprising, a DC plasma torch and an operating voltage power supply, wherein the power supply is at least two times the average operating voltage used, resulting in a more stable operation of the torch.
  • Additional embodiments include: the apparatus described above where the torch includes concentric cylinder electrodes; the apparatus described above where the power supply has the capability of igniting the torch at a pulse voltage of at least 20 kilovolts; the apparatus described above where the power supply contains inductive filters distributed among positive and negative legs of a regulator to prevent conducted emissions caused by the plasma torch and/or igniter from feeding back into sensitive electronic components; the apparatus described above including filtering elements that causes sensitive electronic components to be exposed to 50% less energy in the form of voltage or current in an instantaneous or cumulative measurement; the apparatus described above where the power supply contains filtering elements at the output of a chopper regulator to shunt high frequency energy; the apparatus described above where the power supply contains chopper regulators in a parallel configuration to achieve redundancy; the apparatus described above where the power supply contains chopper regulators in a series-parallel configuration to allow the use of lower blocking voltages; and the apparatus described above where the electrodes comprise graphite.
  • FIG. 1 shows a schematic representation of typical torch as described herein.
  • FIG. 2 shows a schematic representation of typical system as described
  • a typical DC (direct current) power supply for a DC plasma arc torch will typically be sized such that its maximum voltage is on the order of 35% above the anticipated operating voltage of the torch.
  • the arc behavior can be erratic, for example, exhibited by large fluctuations in voltage to the arc, or even in the extinguishing of the arc.
  • a maximum power supply voltage that is on the order of two times greater than average operating voltage should be used. This will result in the reducing and minimizing the fluctuations in voltage to the arc and substantial elimination of the arc extinguishing.
  • a higher voltage pulse e.g., 20 kilovolts (kV)
  • kV kilovolts
  • an appropriate capacitive filter is also required to prevent damage to the sensitive electronic components that control the power electronic switching devices.
  • concentric cylinder graphite rods are used, without a power supply appropriately sized as described herein (e.g., larger than typically used with conventional DC plasma torches) the process would simply not be able to be run stably.
  • Operating the torch in a power regulating mode also helps to reduce voltage fluctuations.
  • most torches run in current regulated mode, where the power supply is given a current setpoint, and the power supply then adjusts its output voltage in order to keep the current at the setpoint, regardless of the load voltage.
  • Power regulated mode is where the power supply is given a power setpoint, and the power supply then adjust both the output voltage and the current in order to keep the output power at the setpoint.
  • Running in power regulated mode would substantially reduce the voltage fluctuations, but could lead to the arc extinguishing more often if the current and voltage drifted too far apart and the current gets too low. This can be overcome by operating with a threshold at which the power supply would switch back into current regulated mode in order to keep the arc alive, and then raising the current setpoint and switching back to power regulated mode once the current was high enough.
  • a threshold at which the power supply would switch back into current regulated mode in order to keep the arc alive and then raising the current setpoint and switching back to power regulated mode once the current was high enough.
  • FIG. 1 A typical torch useful with the present invention is shown schematically in FIG. 1 .
  • the concentric cathodes ( 10 ) and anodes ( 11 ) form the annulus through which conventional plasma forming gas can be supplied ( 12 ) between the electrodes ( 10 and 11 ).
  • FIG. 2 shows schematically the power supply ( 21 ) connected to a separate torch starter ( 22 ) and used to provide power to the DC plasma torch ( 23 ).
  • the power ranges used will vary depending on such things as the size of the reactor, the distance between the electrodes, etc. And while typical operating voltages can be in the 600-1000 volt range, this can also vary depending on such things as electrode gap, gas composition, pressures and/or flow rates used, etc.
  • Sensitive electronic components are protected through the use of filters as defined herein. Energy is typically shunted through the filter so that the sensitive electronic components are subjected a lower total voltage or current, or rate of change of voltage or current.
  • Appropriate filters include capacitors, LCL (inductive filter), or common mode filter or any other filter of the like.
  • Plasma Voltage the instantaneous voltage of the plasma-arc, which varies as a function of the plasma-arc instantaneous impedance and the instantaneous current output of the power supply
  • Filter an arrangement of inductors and/or capacitors that may include resistive components, used to shunt electrical energy away from or block electrical energy from affecting sensitive electronic components.
  • Sensitive Electronic Components any device that is integral to the electrical design of the power supply and its various subsystems that is susceptible to excessive voltage, current, and/or heat. This may include power electronic switching devices such as Insulated Gate Bipolar Transistors, Power Metal-Oxide-Semiconductor Field Effect Transistors, Integrated Gate Commutating Thyristors, Gate Turn-Off Thyristors, Silicon Controlled Rectifiers, etc.; the control circuits used to switch or “gate” the power electronic switching devices; transient voltage surge suppression devices; capacitors, inductors, and transformers.
  • power electronic switching devices such as Insulated Gate Bipolar Transistors, Power Metal-Oxide-Semiconductor Field Effect Transistors, Integrated Gate Commutating Thyristors, Gate Turn-Off Thyristors, Silicon Controlled Rectifiers, etc.
  • the control circuits used to switch or “gate” the power electronic switching devices transient voltage surge suppression devices; capacitors, inductors, and transformers.
  • Chopper Regulator alternate term for a buck regulator, including the traditional topology and all variations, wherein the input DC voltage to the converter is “chopped” using a PWM (pulse width modulation) controlled electronic switch to some lower output voltage.
  • PWM pulse width modulation
  • Snubber Circuit a protection circuit placed in parallel with a power electronic switching device, the purpose of which is to limit high rates of change of voltage across and/or current through the device.
  • Smoothing Reactor refers to either an inductor used as the storage element in a traditional buck/chopper regulator, or an inductor used to limit current ripple at the output of a DC-DC converter.
  • a DC concentric cylinder, graphite electrode, plasma torch is operated using an average operating voltage of 300-500 volts.
  • the power supply to operate the plasma torch has a voltage generating capability of at least two times the average operating voltage needed, i.e. 1000 volts. This results in a much more stable operation of the torch as described herein.
  • a separate starter power supply also has the capability of igniting the torch at a pulse voltage of at least 20 kilovolts.
  • the starter power supply contains an appropriate amount of capacitive filtering to shunt unwanted energy away from sensitive electronic components.
  • a topology for implementing the system described in Example 1 is as follows.
  • a 6, 12, 18, or 24-pulse rectifier is used as the front end AC-DC converter.
  • This rectifier can be phase-controlled or naturally commutated, with a capacitive output filter, and with or without a commutating output choke.
  • Several chopper regulators composed of power electronic switching devices, snubber circuits, and gating control circuits are used to control the current applied to the load. These chopper regulators can be placed in a parallel configuration to add redundancy, or in a series-parallel configuration to also allow for the use of devices with lower blocking voltages.
  • Smoothing reactors are used as the main energy storage device in the current regulator, and are distributed among the positive and negative legs of the regulator to add additional protection for the sensitive power electronics.
  • Capacitors are used as filters on the output of the current regulator to absorb high frequency energy that may arise from the chaotic nature of the plasma torch load.

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  • Physics & Mathematics (AREA)
  • Engineering & Computer Science (AREA)
  • Plasma & Fusion (AREA)
  • Spectroscopy & Molecular Physics (AREA)
  • Fluid Mechanics (AREA)
  • Plasma Technology (AREA)
  • Physical Or Chemical Processes And Apparatus (AREA)
US15/221,088 2015-07-29 2016-07-27 Dc plasma torch electrical power design method and apparatus Abandoned US20170034898A1 (en)

Priority Applications (3)

Application Number Priority Date Filing Date Title
US15/221,088 US20170034898A1 (en) 2015-07-29 2016-07-27 Dc plasma torch electrical power design method and apparatus
US16/892,199 US11665808B2 (en) 2015-07-29 2020-06-03 DC plasma torch electrical power design method and apparatus
US18/137,918 US12250764B2 (en) 2015-07-29 2023-04-21 DC plasma torch electrical power design method and apparatus

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US201562198431P 2015-07-29 2015-07-29
US15/221,088 US20170034898A1 (en) 2015-07-29 2016-07-27 Dc plasma torch electrical power design method and apparatus

Related Child Applications (1)

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US16/892,199 Continuation US11665808B2 (en) 2015-07-29 2020-06-03 DC plasma torch electrical power design method and apparatus

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US16/892,199 Active 2036-08-16 US11665808B2 (en) 2015-07-29 2020-06-03 DC plasma torch electrical power design method and apparatus
US18/137,918 Active US12250764B2 (en) 2015-07-29 2023-04-21 DC plasma torch electrical power design method and apparatus

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Country Status (5)

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US (3) US20170034898A1 (fr)
CN (2) CN111601447A (fr)
CA (1) CA3032246C (fr)
MX (1) MX2018001259A (fr)
WO (1) WO2017019683A1 (fr)

Cited By (19)

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WO2018165483A1 (fr) 2017-03-08 2018-09-13 Monolith Materials, Inc. Systèmes et procédés de production de particules de carbone à l'aide un gaz de transfert thermique
US10100200B2 (en) 2014-01-30 2018-10-16 Monolith Materials, Inc. Use of feedstock in carbon black plasma process
US10138378B2 (en) 2014-01-30 2018-11-27 Monolith Materials, Inc. Plasma gas throat assembly and method
US10370539B2 (en) 2014-01-30 2019-08-06 Monolith Materials, Inc. System for high temperature chemical processing
US10618026B2 (en) 2015-02-03 2020-04-14 Monolith Materials, Inc. Regenerative cooling method and apparatus
US10808097B2 (en) 2015-09-14 2020-10-20 Monolith Materials, Inc. Carbon black from natural gas
US11149148B2 (en) 2016-04-29 2021-10-19 Monolith Materials, Inc. Secondary heat addition to particle production process and apparatus
US11304288B2 (en) 2014-01-31 2022-04-12 Monolith Materials, Inc. Plasma torch design
US11453784B2 (en) 2017-10-24 2022-09-27 Monolith Materials, Inc. Carbon particles having specific contents of polycylic aromatic hydrocarbon and benzo[a]pyrene
US11492496B2 (en) 2016-04-29 2022-11-08 Monolith Materials, Inc. Torch stinger method and apparatus
US11665808B2 (en) 2015-07-29 2023-05-30 Monolith Materials, Inc. DC plasma torch electrical power design method and apparatus
US11760884B2 (en) 2017-04-20 2023-09-19 Monolith Materials, Inc. Carbon particles having high purities and methods for making same
US11939477B2 (en) 2014-01-30 2024-03-26 Monolith Materials, Inc. High temperature heat integration method of making carbon black
US11979974B1 (en) * 2020-06-04 2024-05-07 Inno-Hale Ltd System and method for plasma generation of nitric oxide
US11987712B2 (en) 2015-02-03 2024-05-21 Monolith Materials, Inc. Carbon black generating system
US12030776B2 (en) 2017-08-28 2024-07-09 Monolith Materials, Inc. Systems and methods for particle generation
US12119133B2 (en) 2015-09-09 2024-10-15 Monolith Materials, Inc. Circular few layer graphene
US12378124B2 (en) 2017-08-28 2025-08-05 Monolith Materials, Inc. Particle systems and methods
US12497517B1 (en) 2024-07-19 2025-12-16 Monolith Materials, Inc. Method of making carbon black

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WO2017019683A1 (fr) 2017-02-02
US20230354501A1 (en) 2023-11-02
US11665808B2 (en) 2023-05-30
CN111601447A (zh) 2020-08-28
US12250764B2 (en) 2025-03-11
US20210120658A1 (en) 2021-04-22
CN108292826B (zh) 2020-06-16

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