Gas product manufacturing systems, processing chambers, and methods for the use thereof

Abstract

The present disclosure relates to a gas product manufacturing system that includes a processing chamber, wherein the processing chamber has a plurality of electrodes penetrating the processing chamber, and the chamber bottom portion includes a funnel wall positioned below a quench fluid inlet as well as between the plurality of electrodes and a gas outlet. A benefit of the gas product manufacturing system can be eliminating or reducing the need for pressure adjustments before, after, and during processing. A benefit of the gas product manufacturing system can be selectively providing a variety of gas outputs as well as high quality carbon materials.

Description

Attorney Docket No.: ResolHgPCT GAS PRODUCT MANUFACTURING SYSTEMS, PROCESSING CHAMBERS, AND METHODS FOR THE USE THEREOF CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This Application claims priority to U.S. Provisional No.63 / 545,687, filed on October 25, 2023 and U.S. Provisional 63 / 634,340, filed on April 15, 2024, the entirety of which are incorporated by reference. TECHNICAL FIELD

[0002] The present disclosure relates to gas product manufacturing systems, gas processing chambers, and methods for the use thereof, wherein the gas product manufacturing system includes a processing chamber equipped with a feed fluid inlet for fluid input and a gas outlet for extracting gas products. The gas product manufacturing system can be operable at a wide variety of pressures, eliminating the need for pressure adjustments before, after, and during processing. Additionally, the gas product manufacturing system can provide a variety of gas outputs as well as high quality carbon materials. BACKGROUND

[0003] Producing clean, reliable hydrogen is considered critical for providing sustainable energy. The hydrogen generation market was estimated at $158.8 billion in 2023 and is expected to grow to reach $257.9 billion by 2028 and $1.4 trillion by 2050. The clean, reliable production of gases such as hydrogen gas is considered essential for many industrial chemical processes.

[0004] A significant portion of hydrogen production today relies on the production of 'gray' hydrogen, a process that involves steam methane reforming (SMR) of natural gas. Regrettably, this method contributed to approximately 1.8% of global greenhouse gas emissions in 2021. In contrast, low-carbon hydrogen is emerging as a more sustainable alternative, primarily produced through two distinct methods: 'blue' hydrogen, generated using SMR with carbon capture and storage, and 'green' hydrogen, produced via the electrolysis of water using renewable energy sources. However, as of 2021, low-carbon hydrogen production accounted for less than 1% of the overall hydrogen supply.

[0005] The major application sectors for hydrogen are oil refining (43% of consumption in 2021) and industrial processes (57%). Industrial usage primarily involves ammonia production for fertilizers and the manufacture of methanol.

[0006] In the context of mitigating global warming and aligning with the goal of limiting the increase in average global temperature to 1.5°C, the future of hydrogen production is expected to transition away from gray hydrogen. The envisioned hydrogen economy of the future emphasizes the extensive adoption of 'blue' and predominantly 'green' hydrogen productionAttorney Docket No.: ResolHgPCT techniques. This transition is anticipated to result in increased total hydrogen production, aimed at serving a broader range of applications. These applications are expected to extend to heavy industries, encompassing processes such as high-temperature operations and electrification, the production of green ammonia and organic chemicals, and the substitution of coal-derived coke in steelmaking. Moreover, hydrogen is anticipated to play a pivotal role in the long-haul transport sector, including shipping, aviation, and, to a lesser extent, heavy goods vehicles. Furthermore, hydrogen's role in long-term energy storage solutions is expected to become increasingly significant.

[0007] ‘Syngas,’ short for synthesis gas, is a composite gas mixture comprising varying proportions of hydrogen and carbon monoxide. This gas blend often carries impurities, such as nitrogen, carbon dioxide, and methane. For many downstream chemical processes, it is imperative to separate and remove these impurities before the syngas can be effectively harnessed.

[0008] The downstream chemical applications of syngas encompass an array of critical industrial processes. These include the production of methanol, which serves as a precursor for the synthesis of acetic acid and various acetates. Additionally, syngas is employed in the production of liquid fuels like diesel and aviation fuel, as well as lubricants through processes such as the Fischer-Tropsch method and, formerly, the Mobil methanol to gasoline conversion process. Syngas also plays a pivotal role in ammonia production through the Haber process, facilitating the conversion of atmospheric nitrogen (N2) into ammonia, a vital component of fertilizers. Moreover, syngas is instrumental in the synthesis of oxo alcohols through an intermediate aldehyde.

[0009] Pyrolysis of methane has been investigated for several decades as a means to separate hydrogen from carbon, generate a hydrogen gas and solid carbon product. However, numerous difficulties have been encountered in attempting to commercialize these approaches. Typically, the temperature at which these reactions occur results in poor hydrogen conversion and numerous heavier hydrocarbons that lead to reactor fouling and plugging.

[0010] Catalysts have been investigated for these reactors as a means to increase hydrogen yield, and numerous catalyst chemistries have been identified that can do this. They typically suffer from deactivation as the byproduct of the cracking process tends to cover the active sites and deactivate the catalyst quickly.

[0011] Some companies are developing reactor designs that utilize thermal plasma to heat the inlet gas – usually natural gas, landfill, digester gas, flare gas or other high hydrocarbon content sources. These reactors have relatively low throughput compared to heavy industry requirements, and typically operate at atmospheric or low pressure.Attorney Docket No.: ResolHgPCT

[0012] In some other conventional systems, a plasma torch is utilized, being supplied with a three-phase current. These conventional designs typically utilize well understood plasma torch technology, either with AC or DC electrode configurations, and require a carrier gas to generate and distribute the plasma. This configuration enables plasma generation for the cracking operation, which leads to complexities and cost implications for the manufacturing process. The process of supplying three-phase current requires additional electrical infrastructure and control systems, thereby adding complexity to the setup and potentially increasing production costs. Furthermore, the reliance on the three-phase current can limit the accessibility of these systems to industries where such infrastructure is not readily available or cost-effective to implement.

[0013] Furthermore, many of these conventional system designs face challenges in scalability and environmental sustainability. As the scale of gas production operations increases, maintaining the necessary reaction conditions becomes more challenging, potentially limiting the applicability of the systems to large-scale production. Additionally, the reliance on hydrocarbons such as natural gas or methane raises concerns about environmental impact and long-term sustainability. The carbon footprint associated with using fossil fuel-derived hydrocarbons further complicates the environmental considerations of these systems.

[0014] There remains a need for systems that provide solutions to at least the above-mentioned challenges. There remains a need for a more sophisticated and adaptable gas product manufacturing system. SUMMARY

[0015] The present disclosure provides gas product manufacturing systems. In some embodiments, the gas product manufacturing system includes a processing chamber that includes a feed fluid inlet, a gas outlet, a quench fluid inlet, a chamber bottom portion, and a chamber interior surface, wherein the processing chamber has a plurality of electrodes penetrating the processing chamber, and the chamber bottom portion includes a funnel wall, wherein the funnel wall is positioned below the quench fluid inlet, wherein the funnel wall protrudes from the chamber interior surface toward the chamber bottom portion, and wherein the funnel wall is positioned between the plurality of electrodes and the gas outlet.

[0016] In some embodiments of the gas product manufacturing system, the plurality of electrodes includes from 2 to 20 electrodes or wherein at least one electrode of the plurality of electrodes includes a graphite material, or wherein at least one electrode of the plurality of electrodes includes a width of about 3.0 cm to about 122.0 cm, or wherein at least one electrode of the plurality of electrodes has an electrode top, an electrode bottom, and an electrode side, and wherein at least a portion of the electrode side is in contact with a ceramic coating layer, or wherein at least one electrode of the plurality of electrodes has an electrode top, an electrodeAttorney Docket No.: ResolHgPCT bottom, and an electrode side, and wherein the electrode penetrates into the processing chamber through an electrode seal, or wherein at least one electrode of the plurality of electrodes has an electrode top, an electrode bottom, and an electrode side, and wherein the electrode penetrates into the processing chamber through an electrode seal, wherein the electrode seal includes a ceramic fiber material in contact with the electrode side, or wherein the plurality of electrodes is from 2 to 12 electrodes, and wherein an electrode of the plurality of electrodes has an electrode top, an electrode bottom, and an electrode side, and wherein at least a portion of an electrode side is in contact with a ceramic coating layer, and wherein the electrode penetrates into the processing chamber through an electrode seal, and wherein the electrode seal includes a ceramic fiber material in contact with the ceramic coating layer. In some embodiments, a ceramic fiber material includes a fiber made of a ceramic, such as a silica, an alumina, or any combination thereof. In some embodiments, a ceramic fiber material excludes any substance other than a fiber made of a ceramic, such as a silica, an alumina, or any combination thereof. In some embodiments, ceramic coating includes a layer or paste that includes a ceramic material, such as a silica, an alumina, or any combination thereof.

[0017] In some embodiments of the gas product manufacturing system, the feed fluid inlet includes a fluid inlet nozzle that protrudes from the chamber interior surface, or wherein the feed fluid inlet includes from 1 to 20 fluid inlet nozzles, or wherein the fluid inlet nozzle has from 1 to about 30 inlet nozzle openings, or wherein the fluid inlet nozzle protrudes a fluid inlet nozzle longest distance of from about 1.0 cm to about 25.0 cm from the chamber interior surface, wherein the fluid inlet nozzle has from 1 to 30 inlet nozzle openings, and the inlet nozzle openings have an average internal longest distance across the inlet nozzle openings of from about 0.1 to about 5.0 cm, and a ratio of fluid inlet nozzle longest distance to the average internal longest distance across the inlet nozzle openings of from 2:1 to 250:1, or wherein the processing chamber has an interior chamber width of from about 30.0 cm to about 460.0 cm, and a ratio of an interior chamber height to the interior chamber width is from about 3:1 to about 12:1, or wherein the fluid inlet nozzle includes a fluid inlet nozzle material, wherein the fluid inlet nozzle material includes a steel alloy, a titanium alloy, or a nickel alloy, or any combination thereof.

[0018] In some embodiments of the gas product manufacturing system, the processing chamber includes a heatshield, and at least a portion of the heatshield is positioned between the plurality of electrodes and the fluid inlet nozzle, or wherein the processing chamber includes one or more heatshields, and the feed fluid inlet includes from 1 to 20 fluid inlet nozzles, and at least one portion of one heatshield is located between the plurality of electrodes and one or more of the fluid inlet nozzles.Attorney Docket No.: ResolHgPCT

[0019] In some embodiments of the gas product manufacturing system, the funnel wall forms a funnel opening at a quench fluid level, and wherein the gas outlet is positioned above the quench fluid level.

[0020] In some embodiments of the gas product manufacturing system, the chamber bottom portion includes a bottom valve, and wherein the funnel wall forms a funnel opening above the bottom valve, or wherein the processing chamber includes a heat exchanger beneath or within the chamber interior surface.

[0021] The present disclosure provides processing chambers for producing a gas product. In an some embodiments, the processing chamber includes a feed fluid inlet, a gas outlet, a quench fluid inlet, a chamber bottom portion, and a chamber interior surface, wherein the processing chamber has a plurality of electrodes penetrating the processing chamber, and wherein the chamber bottom portion includes a funnel wall, wherein the funnel wall is positioned below the quench fluid inlet, wherein the funnel wall protrudes from the chamber interior surface toward the chamber bottom portion, and wherein the funnel wall is positioned between the plurality of electrodes and the gas outlet.

[0022] The present disclosure provides methods of producing a gas product. In some embodiments, the method includes providing a processing chamber, wherein the processing chamber includes having a feed fluid inlet, a gas outlet, a quench fluid inlet, a chamber bottom portion, and a chamber interior surface, wherein the processing chamber has a plurality of electrodes penetrating the processing chamber, and wherein the chamber bottom portion includes a funnel wall, wherein the funnel wall is positioned below the quench fluid inlet, wherein the funnel wall protrudes from the chamber interior surface toward the chamber bottom portion, and wherein the funnel wall is positioned between the plurality of electrodes and the gas outlet. In some embodiments, the method includes flowing a feed fluid into the processing chamber through the fluid inlet nozzle, and forming a gas product by applying a voltage among the plurality of electrodes.

[0023] In some embodiments, the method further includes wherein the gas outlet is connected to a gas outlet pipe, and the gas outlet pipe includes a gas outlet temperature sensor, measuring an average operating temperature at the gas outlet temperature sensor of from about 100°C to about 300°C for a temperature measurement duration of 3 minutes; or wherein the gas outlet is connected to a gas outlet pipe, and the gas outlet pipe includes a gas outlet pressure sensor, measuring an average operating pressure at the pressure sensor of from about 150 kPa to about 8000 kPa for a pressure measurement duration of 3 minutes; wherein chamber temperature sensor is located between the funnel wall and the plurality of electrode, measuring an average operating temperature at the chamber temperature sensor of from about 1,200°C to aboutAttorney Docket No.: ResolHgPCT 1,800°C for a temperature measurement duration of 3 minutes; wherein the voltage is an alternating current voltage from about 100 V to about 50 kV; or any combination thereof.

[0024] In some embodiments, the method further includes wherein the feed fluid is a feed liquid, a feed gas, or a feed slurry; or wherein the feed fluid is a hydrocarbon, methane, a flare gas, a natural gas, a syngas, a biogas, a bioliquid, or a molecule containing a carbon atom and a hydrogen atom, or any mixture thereof, or wherein the gas product includes hydrogen gas, or any combination thereof.

[0025] In some embodiments, the method further includes forming a carbon particle inside the processing chamber by applying the voltage among the plurality of electrodes, and collecting the carbon-containing particle by flowing a quench fluid through the quench fluid inlet.

[0026] In some embodiments, the method further includes wherein the chamber bottom portion includes a bottom valve, and wherein the funnel wall forms a funnel opening above the bottom valve, removing the carbon-containing particle from the processing chamber by opening the valve, or wherein the quenching fluid includes water, an aqueous solution, a water slurry, or any combination thereof, or any combination thereof.

[0027] In some embodiments, the method further includes before flowing a feed fluid into the processing chamber, heating the feed fluid to a temperature of about 300°C to about 800°C.

[0028] In some embodiments, the method further includes wherein the processing chamber includes a non-feed fluid nozzle, flowing non-feed fluid through the non-feed fluid nozzle, wherein the non-feed fluid includes O2, H2O, CO2, a non-combustible fluid, or a mixture thereof, and wherein the gas product includes hydrogen and carbon monoxide.

[0029] In some embodiments, the method further includes wherein a production rate of the product gas is from about 1.0 metric tons per day to about 5.0 metric tons per day, or wherein a production rate of the gas product is from about 1.0 metric tons per day to about 1,000.0 metric tons per day. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] The foregoing summary, as well as the following detailed description of the embodiments, will be better understood when read in conjunction with the attached drawings. For the purpose of illustration, there are shown in the drawings some embodiments, which may be preferable. It should be understood that the embodiments depicted are not limited to the precise details shown and are not drawn to scale.

[0031] FIG.1 is a cutaway schematic depiction of an embodiment of a gas processing chamber of an embodiment of the gas product manufacturing system.

[0032] FIG.2 is a cutaway schematic depiction of the gas processing chamber shown in FIG. 1, during operation.Attorney Docket No.: ResolHgPCT

[0033] FIGs.3A, 3B, and 3C are cutaway schematic depictions of embodiments of the processing chamber in embodiments of the gas product manufacturing system, illustrating various integrations of a heat shield, a feed fluid inlet, and a coolant sprayer.

[0034] FIGs.3D and 3 E are schematic depictions of embodiments of the processing chamber in an embodiment of the gas product manufacturing system, showing various orientations of the fluid inlet nozzles.

[0035] FIGs.3F, 3G, and 3H are schematic depictions of embodiments of a fluid inlet nozzle, according to embodiments of the processing chamber in embodiments of the gas product manufacturing system.

[0036] FIG.4 is a schematic of embodiments of the gas product manufacturing system, which includes an embodiment of a gas processing chamber.

[0037] FIG.5 illustrates a flow diagram of an embodiment of a method of producing a gas product.

[0038] FIG.6A is a cutaway schematic depiction of a different embodiment of the gas processing chamber shown in FIG.1, showing a design variation in a top portion of the gas processing chamber.

[0039] FIG.6B is a cutaway schematic depiction of a different embodiment of the gas processing chamber shown in FIG.6A, showing a different design variation in a top portion of the gas processing chamber. DETAILED DESCRIPTION

[0040] Unless otherwise noted, all measurements are in standard metric units.

[0041] Unless otherwise noted, all instances of the words “a,” “an,” or “the” can refer to one or more than one of the word that they modify.

[0042] Unless otherwise noted, the phrase “at least one of” means one or more than one of an object. For example, “at least one of the electrodes” means a single electrode, two electrodes, three electrodes, four or more electrodes, or any combination thereof.

[0043] Unless otherwise noted, the term “about” refers to ±10% of the non-percentage number that is described, rounded to the nearest number to the accuracy shown. For example, about 105.3 mm, would include 94.8 to 115.8 mm. Unless otherwise noted, the term “about” refers to ±5% of a percentage number. For example, about 20% would include 15 to 25%. When the term “about” is discussed in terms of a range, then the term refers to the appropriate amount less than the lower limit and more than the upper limit. For example, from about 100 to about 200 mm would include from 90 to 220 mm.

[0044] Unless otherwise noted, a range of numbers for temperature, pressure, and dimensions, such as length, width, height, diameter, and the like, include all numbers in thatAttorney Docket No.: ResolHgPCT range to the accuracy shown. For example, the range of 1.0 cm-5.0 cm includes 1.0 cm, 2.0 cm, 3.0 cm, 4.0 cm, 5.0 cm, 1.0-3.0 cm, as well as any sub range therein.

[0045] Unless otherwise noted, the term “fluid” refers to a gas, liquid, slurry, or mixture or combination thereof.

[0046] Unless otherwise noted, the term “reaction chamber” can be used interchangeably with “processing chamber.”

[0047] Unless otherwise noted, the term “heat shield” refers to a solid structure or object, which can withstand a temperature of 2000°C to 3980°C for 3 hours without changing shape.

[0048] Unless otherwise noted, the term “chamber bottom portion” refers to an interior portion of processing chamber located closer to the ground or earth than the plurality of electrodes.

[0049] Unless otherwise noted, the terms “provide”, “provided” or “providing” refer to the supply, production, purchase, manufacture, assembly, formation, selection, configuration, conversion, introduction, addition, or incorporation of any element, amount, component, reagent, quantity, measurement, or analysis of any method or system of any embodiment herein.

[0050] There are many challenges to providing high quality, safe, reliable hydrogen gas, especially when trying to scale the production of hydrogen gas to industrially viable levels. Three of the most significant challenges to conventional hydrogen gas production reactors include that conventional hydrogen gas production chambers are limited to converting gasses to hydrogen gas at low pressures, limited in their ability to select which gasses are produced, and limited in their efficiency by the constant fouling of the feed lines into conventional gas reaction chambers, which leads to fouling buildup within the reactor interiors, and even to fouling of the downstream lines.

[0051] Many conventional thermal hydrogen production chambers cannot withstand or operate at high pressures of 150 kPa or above. However, it is industrially unviable to transport and / or store gases without compressing them at high pressures. Therefore, many of the sources of feed gas or fluid, such as flare gas from an oil and gas recovery facility, or carbon dioxide from a tanker truck, are produced, transported, and / or stored at high pressures in excess of 150 kPa. To operate safely, conventional thermal hydrogen production chambers require that the excess pressure of the feed gas be reduced before they are allowed to flow into the reaction chamber. However, such conventional thermal hydrogen production chambers produce gas at low pressures, which are industrially useless until they are re-pressurized for storage and transportation. Therefore, conventional thermal hydrogen production chambers require that the pressure of the feed fluid or gas be lowered or depressurized from industrially useful levels before entering into the reaction chamber and then increased back or re-pressurized toAttorney Docket No.: ResolHgPCT industrially useful levels after being produced. This need to both lower and increase pressure of the gas flowing into and out of the reaction chamber wastes tremendous amounts of energy and limits the scalability of such conventional thermal hydrogen production chambers, which in turn limits their viability to provide the scale of hydrogen production required by the world’s ever- growing need for clean energy.

[0052] Another drawback of this need of conventional reaction chambers to operate at low pressures is that the gas reaction products are often heavily loaded with contaminants, because, at low pressures and / or low temperatures, the feed gas cannot be effectively converted into pure hydrogen gas. Also, the carbon materials produced by incinerating a carbon-containing feed gas tend to be only partially pyrolyzed. The impure gas output, such as hydrogen gas contaminated with heavier hydrocarbon gases, carbon monoxide or carbon nanoparticles, requires purification steps after the reaction chamber to remove such contaminants before the gas output can be purified into pure, useful hydrogen gas.

[0053] It has been discovered that it is possible to design or configure a gas product manufacturing system, which can thermally convert a feed fluid into gas products, including hydrogen gas, while safely maintaining a pressure above 150 kPa, including from about 150 kPa to about 8,000 kPa. It may seem trivial to provide a gas processing chamber capable of withstanding pressures above 150 kPa. However, to do so, several challenges had to be overcome. For example, when thermally converting a carbon containing feed fluid into hydrogen gas, carbon containing particles would have to be produced. To make this an industrially viable process, the carbon containing particles being produced would have to be removed on a continuous basis while somehow maintaining the high pressure for the reactor.

[0054] It has been discovered that a lock hopper design or configuration at the bottom of the gas product manufacturing chamber can allow for carbon containing particles, which continuously form during the reaction, to be continuously removed during the reaction by allowing them to be captured by a continuously supplied quenching fluid. The quenching fluid containing the carbon-containing particles can then be flowed down a funnel wall into a quench bath 246 and removed in frequent batches by opening and closing a valve while the maintaining high pressure of the reaction within the gas product manufacturing system. Further, it has been found that a combination of high pressures, such as above 150 kPa, including from about 150 kPa to about 8,000 kPa, and high temperatures, such as from about 1,200°C to about 1,200°C and above, can almost completely convert a carbon containing feed fluid, such as hydrocarbons, into pure hydrogen gas and a high-quality carbon-containing particle. Further, the capture of the carbon-containing particles in a quench bath having quench fluid level, can be used together with funnel walls and funnel openings to efficiently separate the gas product from the quench fluidAttorney Docket No.: ResolHgPCT containing carbon containing particles because when the valve is opened at the processing chamber, the particles exit the reactor with the quench water, the gases flow out of the gas outlet, and the level in the quench chamber is maintained by increasing the flow of quench fluid into the chamber.

[0055] It might sound trivial to design a gas processing chamber capable of operating at high pressures, such as above 150 kPa, including from about 150 kPa to about 8,000 kPa, and high temperatures, such as from about 1,200°C to about 1,800°C or more. However, to do so, several challenges had to be overcome. For example, to provide an efficient source of clean thermal heat without heating the entire reaction chamber, a continuous, localized source of heating would need to be provided. Such a continuous localized source of heating can be provided by a plurality of electrodes and plasma induced pyrolysis. However, to introduce the plurality of electrodes into the reaction chamber or processing chamber, the plurality of electrodes would need to be safely electrically insulated from the material of the processing chamber and yet would need to have seals in place that were sufficient to withstand high pressures, such as above 150 kPa, including from 150 kPa to about 8,000 kPa, and high temperatures, such as from about 1,200°C to about 1,800°C or more. It has been discovered that a combination of a ceramic coating layer and a ceramic fiber material can be used to provide seals that can withstand such high pressures and high temperatures during operation of the processing chamber.

[0056] As mentioned before, another problem associated with conventional thermal processing chambers for producing hydrogen gas from a carbon containing feed fluids has been the fouling of the feed fluid inlets. For example, when feeding a pure hydrocarbon fluid, such as methane, into a thermal reaction chamber being operated at a temperature above the flashpoint of the hydrocarbon fluid, the hydrocarbon fluid would be partially pyrolyzed into hydrogen gas and a carbon containing residue, where in the carbon containing residue would be formed at the opening of the feed fluid inlet. During the continuous operation needed for an industrially viable gas producing process, the carbon containing residue or char builds up blocking the feed fluid inlet. This fouling of the feed fluid inlets requires that conventional gas processing chambers and systems be shut down frequently for the cleaning and removal of the carbon containing residue from the feed fluid inlets. If the feed flow inlets are just openings in the chamber wall, then the cleaning and removal of the carbon containing residue is difficult and time consuming. To reduce the rate of formation of the carbon containing residue, many conventional gas processing chambers and conventional gas processing systems require a carrier fluid to be added to the feed fluid as it enters the feed fluid inlet into the chamber, so as to dilute the amount of carbon containing fluid in the feed fluid stream. However, it is inefficient to reduce the flow of theAttorney Docket No.: ResolHgPCT carbon containing fluid to be converted into gas products by deliberately diluting it with carrier gases, such as nitrogen or hydrogen.

[0057] It has been discovered that it is possible to provide a reaction chamber with one or more feed fluid inlets having feed fluid nozzles, wherein the feed fluid nozzles are configured or shaped to spread the feed fluid into fine streams other fluid as it enters the processing chamber. Further, it has been discovered that locating these feed flows at nozzles in a temperature controlled zone located between the high temperature top of the processing chamber and the quench bath at the bottom of the processing chamber can prevent or reduce the formation of carbon containing residues within the feed fluid inlets. That is, the location and shape of the feed fluid nozzles allows for the feed fluid to enter the chamber completely through the feed fluid inlet and to be thermalized after having left the feed fluid inlet. This configuration of feed fluid inlets having or through feed fluid nozzles also can have the additional benefit of allowing for a pure feed fluid, excluding any carrier gas or fluid, to be flowed into the processing chamber, which results in tremendous efficiency because 100% of the feed fluid can be the fluid to be reformed as opposed to a mere diluted fraction as in conventional processing chambers. This configuration of feed fluid inlets having or through feed fluid nozzles also can have the additional benefit of allowing for the feed fluid flowing through the feed fluid nozzles to be heated before entering the processing chamber. Further, a benefit of feed fluids passing through a feed fluid nozzle that is reversibly removable can allow for the quick and easy cleaning of the feed fluid inlets when and if any carbon containing residue forms at the openings of the feed fluid nozzles. That is, the feed fluid nozzles can be quickly and easily replaced during cleaning, allowing the processing operations to resume while the dirty feed fluid nozzles are cleaned outside of the gas processing chamber.

[0058] As an aside, the present disclosure provides gas processing chambers and methods that reform, rather than merely pyrolyze fluids. Reforming can be thought of as reshaping hydrocarbons into more useful molecules. When the hydrocarbon reacts with oxygen containing compounds such as CO2, H2O or even O2 these are reforming reactions, usually making more useful H2 and CO. Pyrolysis is reforming in the absence of O2 containing molecules so is heat driven and produces the solid carbon and / or other higher hydrocarbons.

[0059] It might sound trivial to provide feed fluid inlets with feed fluid nozzles that extend into the processing chamber beyond the chamber walls and located between a high temperature zone at the top or plasma zone of a gas processing chamber, having temperatures of from about 1,200°C to about 1,800°C and above, and a quench fluid at the bottom of the processing chamber. For example, the temperature of the plasma zone is expected to pass above 3,000°C or more during operation. However, this layout adds the additional challenge of preventing orAttorney Docket No.: ResolHgPCT reducing the high temperatures of the high temperature zone of the gas processing chamber from melting the feed fluid nozzles and converting the quenching bath into steam and char during operation.

[0060] It has been found that a heat shield can be located between the plurality of electrodes and the feed fluid inlet having the feed fluid nozzles. This configuration can prevent or reduce the high temperatures of the gas processing chamber from melting or damaging the feed fluid nozzles. Further, it has been found that heat exchangers can be located between the plurality of electrodes and the quench fluid inlet and quench fluid bath to provide a temperature gradient, controlling and reducing the temperature from the high temperature zone near the plurality of electrodes to a lower temperature zone near the feel fluid nozzles and the quench fluid inlet. A benefit of the heat exchanger can be to control the temperature of the gas processing chamber, to prevent or reduce damage to the feed fluid nozzles, and reduce the conversion of the quench fluid into gas or steam.

[0061] Conventional gas reaction chambers lack the ability to vary their feed gas input and therefore have little or no ability to select which gases are produced. For example, a conventional gas reaction chamber must introduce a feed gas, such as the hydrocarbon methane, diluted in a carrier gas, such as hydrogen or nitrogen. With this reduction of feed efficiency, the introduction of additional non feed fluids, such as water, carbon dioxide, or oxygen makes these processes even more industrially unviable.

[0062] A benefit of the gas processing chamber and gas processing systems disclosed herein can be the introduction of a pure feed fluid that excludes or reduces any carrier gas and introduces non-feed gasses, such as water, carbon dioxide, oxygen, and combination thereof. This improved ability to control which reactants efficiently flow into the gas processing chamber allows for the gas processing chamber to select or control which gas products are produced. For example, flowing a pure hydrocarbon into the gas processing chamber would produce hydrogen gas and carbon containing particles. However, if a mixture of hydrogen gas and carbon monoxide were desired instead, then water, carbon dioxide, and / or oxygen can be flowed into the processing chamber through non feed gas nozzles or inlets, along with the hydrocarbon gas through the feed fluid inlet, providing a mixture of hydrogen gas and carbon monoxide as a gas output.

[0063] The gas processing chamber, gas processing system, and methods for the use thereof are presented in more detail below. System

[0064] In some embodiments, a gas product manufacturing system 100 is disclosed. Referring to FIG.1, in some embodiments, the gas product manufacturing system 100 includes aAttorney Docket No.: ResolHgPCT processing chamber 104 that is configured with a chamber interior surface 106. In some embodiments, the processing chamber 104 includes three portions such as a top portion, a middle portion, and a bottom portion. In some embodiments, the top portion includes a plurality of electrodes 102 that extend or penetrate from outside the processing chamber 104 through openings and seals to the inside of the processing chamber 104. In some embodiments, the processing chamber 104 includes a feed fluid inlet 110, a non-feed gas nozzle 112 (e.g., a non- feed fluid nozzle), a quench fluid inlet 116, and a heat exchanger 130 at the middle portion. In some embodiments, the heat exchanger 130 can be located beneath the feed fluid inlet 110. In some embodiments, at least a portion of a heat shield 108 is positioned between the top portion and the middle portion. In some particular embodiments, the heat shield 108 can be positioned between the plurality of electrodes 102 and the feed fluid inlet 110. In some embodiments, the processing chamber 104 includes a gas outlet 118, a chamber bottom portion 122C, and a funnel wall 124 in the bottom portion. In some embodiments, the chamber bottom portion 122C includes a bottom valve 128. In some embodiments, the funnel wall 124 is positioned below the quench fluid inlet 116 and protrudes from the chamber interior surface 106 toward the chamber bottom portion 122C. In some embodiments, the funnel wall 124 is positioned between the plurality of electrodes 102 and the gas outlet 118. In some embodiments, the funnel wall 124 forms a funnel opening 126 located above the bottom valve 128.

[0065] In some embodiments, the feed fluid inlet 110 includes a fluid inlet nozzle 114 that protrudes from the chamber interior surface 106. In some embodiments, the processing chamber 104 includes one or more heat shields 108 and the feed fluid inlet 110. In some embodiments, a portion of one heat shield 108 is located between the plurality of electrodes 102 and one or more of the fluid inlet nozzles 114. In some embodiments, the funnel wall 124 forms the funnel opening 126 at a quench fluid level. In some embodiments, the gas outlet 118 is positioned above the quench fluid level. In some embodiments, a baffle 120 and / or separation wall 132 is positioned between the gas outlet 118 and the quench fluid level 136 to separate them and ensure proper flow control. In some embodiments, the chamber bottom portion 122C includes the bottom valve 128, and the funnel wall 124 forms the funnel opening 126 above the bottom valve 128.

[0066] Referring to FIGs.1 and 2, in some example embodiments, each electrode 102 of the plurality of electrodes 102 includes a graphite material. In some embodiments, each electrode 102 has an electrode top 202, an electrode bottom 210, and an electrode side 204. In some embodiments, at least a portion of the electrode side 204 is in contact with a ceramic coating layer 206. In some embodiments, each electrode 102 penetrates the processing chamber (e.g., 104 as illustrated in FIG.1) through an electrode seal that includes a ceramic fiber material 208Attorney Docket No.: ResolHgPCT that is in contact with the electrode side 204. In some embodiments, each electrode 102 is conducts or can conduct voltage from outside to inside the processing chamber 104 and, in terms of material and dimensions, to create and sustain an arc plasma 212 at the top portion of a processing chamber (e.g., the processing chamber 104). In some embodiments, the voltage is an Alternating Current (AC) voltage ranging from about 100 V to about 50 kV, but is not limited to this range. In some embodiments, each electrode 102 has the ceramic coating layer 206, and the ceramic fibers contain material surrounding the part of each electrode 102 that passes through the electrode seal. In these embodiments, the ceramic coating layer 206 and the ceramic fiber material 208 are part of the electrode seal. In some embodiments, the ceramic coating layer 206 and the ceramic fiber material 208 are used to insulate the processing chamber 104 from the currents passed through the electrodes 102 and to provide a pressure seal.

[0067] In some embodiments, the ceramic coating layer 206 and the ceramic fiber material 208 can have the ability to withstand high temperatures generated within the processing chamber 104. In some embodiments, ceramic seals (e.g., the electrode seal) form a pressure seal, allowing the processing chamber 104 to be pressurized to high pressures. In some embodiments, the top portion of the processing chamber 104 has the highest temperature that can effectively incinerate feed gas into a carbon-containing particle 238. In some embodiments, the feed fluid inlet 216 (or 110 as illustrated in FIG.1) is configured or shaped as fluid inlet nozzles (e.g., 114 as illustrated in FIG.1) that extend into the processing chamber 104. In some embodiments, the feed fluid inlet 216 is configured with or shaped to have multiple inlet nozzle openings 222 at their tips to separate, modulate, or control the flow of the feed fluid into the processing chamber 104. In some embodiments, this configuration or arrangement can avoid or reduce carbon fouling often associated with large openings in chamber walls. In some embodiments, the design or shape of the fluid inlet nozzles 114 enables a feed fluid to pass the gas into small streams as it enters the processing chamber. In some embodiments, as the fluid inlet nozzles 114 heat up to a temperature ranging from about 300°C to about 800°C, but not limited to this range, the feed fluid undergoes preheating, transforming into a fine stream of heated gas or mist before entering the processing chamber 104. In some embodiments, this stream of feed fluid then arises or mixes within the processing chamber for incineration outside of the feel fluid inlet or feed fluid nozzle. In this way, the nozzle shape can make maintenance easier and faster. In some embodiments, the fluid inlet nozzles are reversibly fastened or attached to the interior chamber surface. In cases of carbon fouling, quick removal, replacement, and cleaning of fluid inlet nozzles 114 is possible outside the processing chamber 104. In some embodiments, the location and orientation of nozzles can also facilitate controlled gas mixing within the processing chamber 104, leading to more efficient mixing and improved production of hydrogen gas and a carbon-containing particleAttorney Docket No.: ResolHgPCT 238. In some embodiments of the gas product manufacturing system and processing chamber for producing a gas product, the feed fluid can include, but is not limited to, a hydrocarbon, a methane, a flare gas, a natural gas, a syngas, a biogas, a bioliquid, or a molecule containing a carbon atom and a hydrogen atom, or any mixture thereof.

[0068] In some embodiments, the feed fluid inlet 216 is designed or shaped to transfer a feed fluid, a gas, a liquid, or a slurry that includes carbon and hydrogen atoms into the processing chamber 104. The inclusion of hydrogen atoms in the feed fluid allows for generating hydrogen gas. Typically, carbon is bound to the hydrogen atoms in these feed fluids and is separated from the hydrogen atoms to provide hydrogen gas by thermalizing or incinerating the feed fluid. Also, the presence of the carbon atoms facilitates combustion or incineration. In some embodiments, the processing chamber can also include a non-feed fluid nozzle 220. In some embodiments, the non-feed fluid nozzle 220 (or 112 as illustrated in FIG.1) can introduce a non-feed fluid that is different from the feed fluid. In some embodiments, the non-feed fluid excludes hydron atoms, carbon atoms, or both. This different fluid can influence the reactions in the processing chamber 104, to yield different gas products or gas product compositions. In some embodiments, by incorporating these non-feed fluid materials, the production can be altered from providing gas products that only include hydrogen gas and carbon particles to a gas product that are a include combination of hydrogen gas with carbon monoxide or hydrogen gas with carbon dioxide, or any mixture thereof. Commonly used non-feed fluids can include, but are not limited to, oxygen, carbon dioxide, carbon monoxide, water, hydrogen gas, or any mixture thereof.

[0069] In some embodiments, the dimensions and layout of the processing chamber 104 provide an incineration zone in the chamber top portion 122A and a quenching zone in the chamber bottom portion 122C, which creates a temperature gradient, where the temperature deceases across chamber middle portion 122B as the air flows from the chamber top of the processing chamber 104 to the chamber bottom portion of the processing chamber 104. In some embodiments, heat exchangers 224 (or 130 as illustrated in FIG.1) can manipulate the rate of decline of the temperature gradient from the top portion of the processing chamber 104 to the bottom portion of the processing chamber 104. By controlling the step down or rate of reduction of the temperature gradient from the top portion to the bottom portion, the processing chamber can avoid damaging the fluid inlet nozzles 114 of the feed fluid inlet 216 due to high temperatures. In some embodiments, the heat exchangers 224 can capture or recapture the energy being expended to create the arc plasma 212 at the top portion of the processing chamber 104 and use that excess energy to power another system such as a turbine (e.g., 432 as illustrated in FIG.4), or to heat some other process, such as an evaporator for purifying water. For example, a portion of the heat can be redirected to the feed fluid inlet 216 prior to reaching the processingAttorney Docket No.: ResolHgPCT chamber 104, serving to heat or partially heat the feed fluid flowing into the processing chamber 104. The heat exchangers 224 in this configuration or layout can contain materials with known heat exchanging properties, like water, aqueous solutions, or molten salts. In some embodiments, these heat exchange materials can flow through the heat exchangers 224, under the interior chamber surface in a direction toward the chamber top, facilitating efficient heat transfer from the chamber interior surface to the heat exchange materials.

[0070] In some embodiments, the bottom portion of the processing chamber 104 has a lock hopper design, configuration, or layout. In some embodiments, the lock hopper includes the funnel wall (e.g., 124 as illustrated in FIG.1) at the bottom portion, with a quench fluid inlet (e.g., 116 as illustrated in FIG.1) for a quench fluid 240 that can flow down the funnel wall 124. In some embodiments, this flow of quench fluid can serve several purposes. The flow of quench fluid can capture the carbon-containing particle 238 being produced. The flow of quench fluid can also contribute to partially cooling both the air within the processing chamber and the processing chamber 104. In some embodiments, the funnel wall 124 leads down to a quench bath at the bottom portion of the processing chamber 104 that captures the carbon-containing particles. In some embodiments, a chamber exit 134, 242 of the processing chamber 104 can contain a bottom valve 128, 244 that opens periodically allowing the carbon particle containing slurry to pass down out of the processing chamber 104 while also allowing the level of the quench bath to fall below the bottom edge of the funnel wall 124, which also allows the gas product to flow below the bottom edge of the funnel wall 124 but above the separation wall and past the baffle (e.g., 120 as illustrated in FIG.1) that separate a gas outlet pipe 228 (or 118 as illustrated in FIG.1) from the quench bath. In some embodiments, this design or configuration allows for the gas product to be separated from the carbon-containing particle containing quench fluid of the quench bath. In some embodiments, the quench liquid entering the processing chamber 104 can be clean, but is typically a recycled slurry, containing carbon-containing particle and quench fluid, that is continuously reused or recycled to capture the carbon- containing particle 238. The quench fluid 240 can include water, an aqueous solution, or a high- temperature fluid such as ethylene glycol, a carbon-containing particle, or mixtures thereof.

[0071] In some embodiments, to measure or monitor the temperature and pressure conditions within the processing chamber 104, a pressure sensor 234 and a gas outlet temperature sensor 236 can be located within or operatively connected to the gas outlet pipe 228. The pressure sensor 234 and the gas outlet temperature sensor 236 can be positioned in contact with, close to, or away from, the processing chamber 104. To reduce contaminants, such as a quench fluid or carbon-containing particle, the gas outlet pipe 228 can be equipped with a filter. These filters can prevent, or reduce the amount of, water or particles from contaminating a gas product 232, as theAttorney Docket No.: ResolHgPCT gas product exits the processing chamber 104. In some embodiments, during operation, the gas outlet temperature sensor 236 can be used to measure an average operating temperature of the gas product 232 within a range from about 100°C to about 300°C, but not limited to this range, for a temperature measurement duration of, for example, 3 minutes. In some embodiments, the pressure sensor 234 is used to measure an average operating pressure of the gas product 232 within a range of about 150 kPa to about 8,000 kPa, but not limited to this range, for a pressure measurement duration of 3 minutes. In some embodiments, the gas product 232 includes, but is not limited to, hydrogen gas, carbon monoxide, carbon dioxide, steam, and mixtures thereof. In some example embodiments, a production rate of the gas product 232 is from about 1.0 metric tons per day to about 5.0 metric tons per day. In some example embodiments, the production rate of the gas product 232 is from about 1.0 metric tons per day to about 1,000.0 metric tons per day.

[0072] In some embodiments, to produce pure hydrogen gas, the feed fluid can be a hydrocarbon, with the non-feed fluid either absent, excluded, or being oxygen to facilitate complete incineration of the hydrocarbon. For example, if the desired product is syngas, then the non-feed fluid can be water, which can react with the feed fluid to produce a mixture of hydrogen gas and carbon monoxide. In some embodiments, a carbon-containing particle 238 is an additional output of the gas product manufacturing system (e.g., 100 as illustrated in FIG.1). The expected high temperature within the system efficiently carbonizes the feed fluid, resulting in pure or nearly pure, highly graphitized carbon particles suitable as feed stocks for nanomaterials or for use in applications like vermiculite production. In some embodiments, the gas product manufacturing system is configured to compact the carbon-containing particles into carbon cakes (e.g., 424 as illustrated in FIG.4). The carbon cakes 424 are expected to be of such high quality, in terms of pure carbonization, they can be profitably provided to the nanomaterials industry as feedstock for research and manufacturing.

[0073] Fig.2 provides an illustration of an embodiment of the gas processing chamber of Fig.1 during operation. In some embodiments, at the top of the processing chamber 104, the feed fluid enters through the feed fluid inlet 216. Optionally, a separate non-feed gas nozzle 220 can allow for the introduction of a non-feed fluid. This heat shield 108 prevents or reduces excessively high temperatures from the arc plasma from damaging the fluid inlet nozzles or incinerating the feed fluid while the feed fluid is withing the feed fluid inlet or feed fluid nozzle. The fluid inlet nozzles 114 having nozzle opening 222 at specific distances (represented as 218) designed or shaped to control the flow and mixing of the gasses within the processing chamber before the air flows up to the top of the processing chamber near the arc plasma 212. In some embodiments, the heat exchanger 224 reduces the heat of the gasses within the processing chamber as the gasses flow toward the bottom of the chamber. In some embodiments, the quenchAttorney Docket No.: ResolHgPCT fluid flows down the funnel walls, capturing carbon-containing particles and flowing into a quench fluid bath located at the bottom of the processing chamber. In some embodiments, the bottom valve is opened, which allows for the removal of a portion to quench fluid and a carbon containing particle through the chamber exit as well as allowing the gas product to flow through the gas outlet pipe. In some embodiments, the gas product flows past the pressure sensor 234 and the gas outlet temperature sensor 236, providing real-time monitoring of the internal conditions. These sensors can ensure that the reaction environment is maintained within the desired parameters for optimal gas production. In some embodiments, the carbon-containing particle 238 generated as by-product of the reaction collects at the chamber bottom portion (e.g., 122C as illustrated in FIG.1). These particles can be removed from the processing chamber 104 through the chamber exit 242, allowing for their collection for potential reuse. In some embodiments, the quench fluid 240 is re-introduced or recycled back into the processing chamber 104 to cool the internal environment and aid in the collection of the carbon-containing particle 238. The design or configuration facilitates the continuous production of gas products 232 separating a carbon- containing particle and a quench fluid. In some embodiments, a chamber temperatures sensor 250 is located between the funnel and the plurality of electrodes, including above the quench fluid inlet and below the heat exchanger, including between the quench fluid inlet and below the heat exchanger.

[0074] Referring to FIG.3A, in some embodiments, the incorporation of heat shield 302 is optional. In some embodiments, suitable refractory materials can be used to construct the heat shield 302. In some embodiments, if the heat shield 302 is included, the heat shield 302 can be positioned in the processing chamber (e.g., 104 as illustrated in FIG.1) between the multiple electrodes 102 and a feed fluid inlet 304. This placement of the heat shiel can prevent or reduce damage to the feed fluid inlet 304 or the fluid inlet nozzles (e.g., 114 as illustrated in FIG.1) from the high temperature generated by the arc plasma (e.g., 212 as illustrated in FIG.2). In some embodiments, the heat shield 302 blocks the direct line of sight from the fluid inlet nozzles 114 to the multiple electrodes 102, while having a shape with openings that allowing for feed fluid and carbon-containing particles formed to flow up to or down from the top of the processing chamber (e.g., 104 as illustrated in FIG.1). The design or shape of the heat shield 302 can be either solid or perforated, the latter allowing temperatures and gases to move more freely within the processing chamber 104. In some embodiments, these perforations can facilitate easier flow within the processing chamber 104. In some embodiments, the fluid feed inlet or fluid inlet nozzles can have one or more connected passages within the material of the fluid feed inlet or fluid inlet nozzles, but separated from the flow of the feed fluid, to allow for a coolant to flow within the walls of the fluid feed inlet or fluid inlet nozzles (not shown). In some embodiments,Attorney Docket No.: ResolHgPCT the sprayers can be located on the chamber interior surface 308 or oriented toward an interior of the processing chamber to assist with the temperature cooling within the processing chamber 104. In some embodiments, coolants can include, but not limited to, water, an aqueous solution, ethylene glycol, or a mixture of these.

[0075] Referring to FIG.3B, in some embodiments, the heat shield 302 can be a raised ring with a depression where the feed inlet nozzles is located, such that the heat shield encircles the feed inlet nozzle (e.g., the feed fluid inlet 304). A benefit of this design or configuration can be preventing or reducing damage to the fluid inlet nozzles from high temperature as well as allowing for precise temperature control of the feed inlet nozzles.

[0076] Referring to FIG.3C, in some embodiments, the feed fluid inlet 304 is recessed within the walls of the chamber interior surface 308, such that the chamber interior surface provides a recessed chamber interior surface 310 that surrounds the feed fluid inlet or non-feed fluid inlet. In some embodiments, in this configuration, the chamber interior surface 308 itself effectively functions as the heat shield 302 for the feed fluid inlet 304. This arrangement or configuration can allow the coolant to be directed toward the entrance of the recessed chamber interior surface, cooling the air allowed to reach the feed fluid inlet, and / or be directed into the center of the processing chamber (e.g., processing chamber 104 as illustrated in FIG.1), cooling of the interior and helping to capture the carbon-containing particle 238. In some embodiments, the configurations depicted in FIGs.3A, 3B, and 3C can be integrated in various combinations. In some embodiments, the heat shield includes graphite, diamond, tantalum hafnium carbide alloy, tantalum carbide (TaC), hafnium carbide (HfC), or a combination thereof.

[0077] Referring to FIGs.3D and 3E, in some embodiments, the orientation of the feed fluid nozzle 304 is shaped or configured to facilitate specific mixing patterns within the processing chamber 104. In some embodiments, as depicted in FIG.3D, the feed fluid inlet 304 are oriented in to oppose the flow of another inlet to promote a mixing pattern characterized by air turbulence and chaotic flow. In some embodiments, the orientation and placement of the feed fluid inlet 304 are oriented to join with the flow of another feed fluid nozzle, facilitating circular mixing. In some embodiments, this circular mixing pattern can be useful in reactions that benefit from enhanced contact between different reactants due to increased collision frequencies. In other words, as illustrated in FIG.3E, in some embodiments, the feed fluid nozzle 304 can be arranged to promote smooth mixing, where the gas is effectively circulated in a circular pattern. This pattern can be favorable for processes where the quality of the end product depends on controlled reaction rates and consistent temperature conditions throughout the reaction space.

[0078] Referring to FIGs.3F, 3G, and 3H, various configurations of the feed fluid inlet 304 are illustrated. In some embodiments, FIG.3F illustrates the feed fluid inlet 304 with curvedAttorney Docket No.: ResolHgPCT tubes, which can be designed or configured with straight tubes having multiple inlet nozzle openings at their tips. In some embodiments, FIG.3G depicts the feed fluid inlet 304 with an array of straight tubes. In some embodiments, FIG.3H illustrates the feed fluid inlet 304 with a different number of inlet nozzle openings, demonstrating a flexibility in design or configuration regarding the curvature of the tubes and the number of nozzle openings. In some embodiments, referring to FIGs.3F, 3G, and 3H, the feed fluid inlet 304 varies not only in shape but also in length, allowing for customized fluid dynamics within the processing chamber 104 to optimize the production process.

[0079] Referring to FIG.4, in some embodiments, the gas product manufacturing system (e.g., 100 as illustrated in FIG.1) includes a power source 402 (AC, DC, induction coil, or a combination thereof), a feed fluid container 406, a feed fluid pump 404, a non-feed fluid container 408, a non-feed fluid container 408, a non-feed fluid pump 410, a gas product container 412, a processing chamber 436, a pressure sensor 414, a gas outlet temperature sensor 420, a chamber exit 416, a filter 428, a secondary separator 418, a device 422 to process carbon particle, a quench fluid recycler 426, a pump 430, a heat exchanger 434, and a turbine 432. In some embodiments, the processing chamber 436 receives AC, DC, or a combination thereof, from the power source 402 to operate the gas product manufacturing system. In some embodiments, the feed fluid container 406 stores the primary fluid that enters the processing chamber 436. The feed fluid container 406 is connected or operatively connected to the feed fluid pump 404. In some embodiments, the feed fluid pump 404 propels the feed fluid from the container 406 into the processing chamber 436, allowing for controlled flow and pressure as required for the reactions. In some embodiments, the non-feed fluid container 408 holds a different fluid used in the gas product manufacturing system, possibly for reactions or for cleaning and maintenance purposes. In some embodiments, the non-feed fluid container 408 is connected or operatively connected to the non-feed fluid pump 410. In some embodiments, the gas product container 412 is where the gas product (e.g., 232 as illustrated in FIG.2) from the processing chamber 436 is stored after processing. In some embodiments, the processing chamber 436 is the central unit that receives the feed fluid and the non-feed fluid. The processing chamber 436 is connected or operatively connected to pressure sensor 414 and the gas outlet temperature sensor 420 to monitor and maintain the desired reaction conditions. In some embodiments, the pressure sensor 414 and the gas outlet temperature sensor 420 can provide real-time data on the internal conditions of the processing chamber 436, ensuring that the gas product manufacturing system operates within safe and optimal parameters. In some embodiments, after processing in the processing chamber 436, the gas product 232 moves out through the chamber exit 416.Attorney Docket No.: ResolHgPCT

[0080] In some embodiments, the secondary separator 418 is positioned between and operatively connected to the chamber exit and a device to process carbon particles. In some embodiments, the secondary separator is positioned between and operatively connected to the chamber exit, a device to process carbon particles, and a quench fluid recycler. A benefit of the secondary separator can be removing a portion of or most of the carbon-containing particles from the quench liquid, such that the carbon-containing particles can be harvested by the device to process carbon containing particle and the quench fluid can be recycled by the quench liquid recycler. In some embodiments, the secondary separator 418 is configured to separate the carbon-containing particle 238 from the fluid to prevent the carbon-containing particle 238 from re-entering the processing chamber 436.

[0081] The quench fluid recycler 426 includes a filter connected or operatively connected to the secondary separator and a pump and pump is operatively connected to the processing chamber. In some embodiments quench fluid recycler is configured to recycle the quench fluid used within the gas product manufacturing system, thereby cleaning and reusing it for quenching or cooling purposes. In some embodiments, the filter 428 is shaped, positioned, or configured to remove particulates from a quench liquid flowing out of the chamber exit, which can include unreacted materials, byproducts, or a carbon-containing particle. A benefit of the filter can be to protect the pump from getting clogged by carbon containing particles and byproducts. In some embodiments, the device 422, such as a compactor or press, is used to process carbon particles and shape or form the carbon-containing particles into carbon cakes 424, likely for disposal, sale, storage, or further processing. In some embodiments, the device 422 can be, but not limited to, carbon black processing units, carbon pelletizers, particle processors, and the like. In some embodiments, the quench fluid recycler 426 is included or excluded from the gas product manufacturing system. In some embodiments, the pump 430 is used for pumping the fluids into the processing chamber 436, such that the pump 430 can be positioned between and operatively connected to the filter 428 and the processing chamber 436. In some embodiments, the heat exchanger 434 is connected to or operatively connected to both the processing chamber 436 and a thermal-utilizing component, such as the turbine 432, which facilitates the recycling and conservation of power. In some embodiments, the heat exchanger 434 can connect to a distillation heating mechanism at an oil refinery. In some embodiments, the turbine 432 is connected or operatively connected to the heat exchanger 434, where the turbine 432 can generate power from the heat extracted by the heat exchanger 434, enhancing the energy efficiency of the gas product manufacturing system. In some embodiments, the chamber exit 416 of the processing chamber 436 can be connected or operatively connected to a quench fluid recycler, which can be the quench fluid recycler 426 or an aqueous fluid recycler. In someAttorney Docket No.: ResolHgPCT embodiments, the aqueous fluid recycler can include the secondary separator 418 to remove as many of the carbon-containing particles as possible before recycling the aqueous fluid, and another filter to again remove many of the carbon-containing particles as needed to allow the quench fluid to be pumped, and the pump 430 to inject the quench fluid back into the processing chamber 436.

[0082] Referring to Fig.6A, in some embodiments of the gas product manufacturing system 600, the design is the same as Figure 1, except the plurality of electrodes 602 is located below the heat shield 608 and the feed fluid inlet 610 or feed fluid nozzle is located above the heat shield. In this embodiment, the plurality our electrodes 602 would extend through the processing chamber 604 past an interior surface of the processing chamber 606. The heat shield would have a form similar to a shower head, surrounding the feed fluid inlet or feed fluid nozzle, but having perforations, which allow air to pass through the end of the heat shield design.

[0083] Referring to Fig.6B, in some embodiments gas product manufacturing system 600 can have no heatshield, or can exclude a heatshield (no drawn), from the processing chamber 604 between the plurality of electrodes 602 the feed fluid inlet 610 or feed fluid nozzle. System Design

[0084] In some embodiments, the heat exchangers (e.g.224 as illustrated in FIG.2) can be located above, around, or within the chamber interior surface (e.g., 106 as illustrated in FIG.1) or any combination thereof. For example, the feed fluid inlet (e.g., 110 as illustrated in FIG.1) can be surrounded by the heat exchangers 224. In some embodiments, the feed fluid inlet 110 includes fluid inlet nozzles (e.g., 114 as illustrated in FIG.1) including, but not limited to, from 1 to 20. In some embodiments, the fluid inlet nozzle 114 has, but not limited to, from 1 to about 30 inlet nozzle openings. In some embodiments, the fluid inlet nozzle 114 protrudes from the chamber interior surface 106, with the fluid inlet nozzle longest distance (e.g., 214 as illustrated in FIG.2) ranging from about 1.0 cm to about 25.0 cm. In some embodiments, the fluid inlet nozzle 114 has, but is not limited to, from 1 to 30 inlet nozzle openings. In some embodiments, the inlet nozzle openings have an average internal longest distance across the fluid inlet nozzle (e.g., 214) openings ranging from about 0.1 cm to about 5.0 cm, but not limited to this range.

[0085] In some embodiments, the ratio of the fluid inlet nozzle’s longest distance (e.g., 214 as illustrated in FIG.2) to the average internal longest distance across the inlet nozzle openings ranges from 2:1 to 250:1, but is not limited to this range. In some embodiments, the processing chamber (e.g., 104 as illustrated in FIG.1) has an interior chamber width (e.g., 226 as illustrated in FIG.2) ranging from about 30.0 cm to about 460.0 cm, but not limited to this range. The ratio of the interior chamber height (e.g., 230 as illustrated in FIG.2) to the interior chamber width 226 is from about 3:1 to about 12:1. In some embodiments, the fluid inlet nozzle 114 can includeAttorney Docket No.: ResolHgPCT a fluid inlet nozzle material such as, but not limited to, a steel alloy, a titanium alloy, or a nickel alloy. In some embodiments, the gas product manufacturing system combines any of these features mentioned in these embodiments. In some embodiments, the plurality of electrodes (e.g., 102 as illustrated in FIG.1) includes, but is not limited to, from 2 to 20 electrodes or from 2 to 12 electrodes. Additionally, in some embodiments, each electrode 102 is configured with a width ranging from about 3.0 cm to about 122.0 cm, but not limited to this range. Method

[0086] FIG.5 illustrates a flow diagram of an embodiment of a method 500 as disclosed herein. In some embodiments, the method 500 is performed by the gas product manufacturing system (e.g., 100 as illustrated in FIG.1). For sake of clarity, method 500 is explained with reference to previous Fig.1 and Fig.2.

[0087] The disclosed embodiments of the gas product manufacturing system 100 provide a solution that includes, in an embodiment, a more efficient method for maintaining elevated pressures within the processing chamber (e.g., 104 as illustrated in FIG.1). In this embodiment, the gas product manufacturing system 100 is configured to produce the gas product (e.g., 232 as illustrated in FIG.2) as per the method 500 shown in FIG.5.

[0088] Referring to FIG.5, in some embodiments of the method, method 500 provides 502 the processing chamber 104 for producing the gas product 232. In some embodiments, the processing chamber 104 includes the feed fluid inlet (e.g., 110 as illustrated in FIG.1), the gas outlet (e.g., 118 as illustrated in FIG.1), the quench fluid inlet (e.g., 116 as illustrated in FIG.1), the chamber bottom portion (e.g., 122C as illustrated in FIG.1), and the chamber interior surface (e.g., 106 as illustrated in FIG.1). In some embodiments, the processing chamber 104 has the plurality of electrodes (e.g., 102 as illustrated in FIG.1) penetrating the processing chamber 104. In some embodiments, the chamber bottom portion 122C includes the funnel wall (e.g., 124 as illustrated in FIG.1). In some embodiments, the funnel wall 124 is positioned below the quench fluid inlet 116, where the funnel wall 124 protrudes from the chamber interior surface 106 toward the chamber bottom portion 122C. In some embodiments, the funnel wall 124 is positioned between the plurality of electrodes 102 and the gas outlet 118.

[0089] Next, in some embodiments, the method 500 includes flowing a feed fluid 504 into the processing chamber 104 through the fluid inlet nozzle (e.g., 114 as illustrated in FIG.1).

[0090] Subsequently, the method 500 includes 506 forming the gas product 232 by applying a voltage among the plurality of electrodes 102.

[0091] In some embodiments, the gas outlet 118 is connected to a gas outlet pipe 228. In some embodiments, the gas outlet pipe 228 includes the gas outlet temperature sensor (e.g., 236 as illustrated in FIG.2). In some embodiments, the method 500 further includes measuring anAttorney Docket No.: ResolHgPCT average operating temperature at the gas outlet temperature sensor 236 of from about 100°C to about 300°C for a temperature measurement duration of 3 minutes. In some embodiments, the gas outlet pipe 228 includes the pressure sensor (e.g., 234 as illustrated in FIG.2). In some embodiments, the method 500 further includes measuring an average operating pressure at the pressure sensor 234 of from about 150 kPa to about 8,000 kPa for a pressure measurement duration of 3 minutes. In some embodiments, the voltage is an AC voltage from about 100 V to about 50 kV. In some embodiments, the method 500 combines any of these features mentioned in these embodiments.

[0092] In some embodiments, the feed fluid is a feed liquid, a feed gas, or a feed slurry. In some embodiments, the feed fluid is a hydrocarbon, a methane, a flare gas, a natural gas, a syngas, a biogas, a bioliquid, or a molecule containing a carbon atom and a hydrogen atom, or any mixture thereof. In some embodiments, the gas product 232 includes hydrogen gas. In some embodiments, the method 500 further includes forming the carbon particle inside the processing chamber 104 by applying the voltage among the plurality of electrodes 102. In some embodiments, the method 500 further includes collecting the carbon-containing particle by flowing a quench fluid (e.g., 240 as illustrated in FIG.2) through the quench fluid inlet 116.

[0093] In some embodiments, the chamber bottom portion 122C includes the bottom valve (e.g., 128 as illustrated in FIG.1). In some embodiments, the funnel wall 124 forms the funnel opening (e.g., 126 as illustrated in FIG.1) above the bottom valve 128. In some embodiments, the method 500 further includes removing the carbon-containing particle from the processing chamber 104 by opening the bottom valve 128. In some embodiments, the quench fluid includes water, an aqueous solution, a water slurry, or any combination thereof. In some embodiments, the method 500 combines any of these features mentioned in these embodiments. In some embodiments, before flowing a feed fluid into the processing chamber 104, the method 500 further includes heating the feed fluid to a temperature of about 300°C to about 800°C.

[0094] In some embodiments, the processing chamber 104 includes the non-feed fluid nozzle (e.g., 112 as illustrated in FIG.1). In some embodiments, the method 500 further includes flowing non-feed fluid through the non-feed fluid nozzle 112. In some embodiments, the non- feed fluid includes O2, H2O, CO2, a non-combustible fluid, or a mixture thereof. In some embodiments, the gas product 232 includes hydrogen and carbon monoxide. In some embodiments, a production rate of the gas product 232 is from about 1.0 metric tons per day to about 5.0 metric tons per day. In some embodiments, a production rate of the gas product 232 is from about 1.0 metric tons per day to about 1,000.0 metric tons per day.

[0095] A benefit associated with method 500 is maintaining the necessary high-pressure conditions within the processing chamber 104. This benefit is particularly significant in someAttorney Docket No.: ResolHgPCT embodiments wherein multiple sealed penetrations ensure the integrity of the gas product manufacturing system 100, and the funnel wall 124 positioned between the electrodes 102 and the gas outlet 118 enhances the functionality of the gas product manufacturing system 100 by facilitating the collection of carbon-containing particle (e.g., 238 as illustrated in FIG.2) while allowing the gas product 232 to exit smoothly.

[0096] A challenge in the existing gas production systems is their substantial carbon footprint, primarily due to the reliance on fossil fuel-derived hydrocarbons like natural gas or methane. This reliance contributes to greenhouse gas emissions and environmental degradation, affecting the sustainability of the gas production process. The disclosed embodiments of the gas product manufacturing system 100 incorporate sustainable feedstock options and implement carbon capture technologies. By diversifying feed fluid sources to include renewable or low- carbon alternatives, such as biogas or biomass-derived fluids, the gas product manufacturing system 100 reduces its overall carbon footprint. Additionally, advanced carbon capture and utilization techniques capture carbon emissions generated during the gas production process, further minimizing environmental impact.

[0097] Yet another challenge in existing gas production systems is the generation of carbon- containing particle 238, which can contribute to air pollution and environmental contamination if not properly managed. These particles can pose health risks and environmental hazards, necessitating effective containment and disposal methods. The disclosed embodiments of the gas product manufacturing system 100 incorporate efficient particle capture and disposal mechanisms. The gas product manufacturing system 100 utilizes the quench fluid 240 to rapidly cool and capture the carbon-containing particle 238 produced during the reforming process, preventing their release into the environment. Additionally, the gas product manufacturing system 100 can include filtration and separation technologies to further purify the gas product 232 and remove any remaining particles before emission. System and Methods

[0098] Embodiments of a method of producing a gas product are disclosed. In some embodiments, the method includes providing a processing chamber, wherein the processing chamber includes having a feed fluid inlet, a gas outlet, a quench fluid inlet, a chamber bottom portion, and a chamber interior surface, wherein the processing chamber has a plurality of electrodes penetrating the processing chamber. In some embodiments, the chamber bottom portion includes a funnel wall, wherein the funnel wall is positioned below the quench fluid inlet, wherein the funnel wall protrudes from the chamber interior surface toward the chamber bottom portion, and wherein the funnel wall is positioned between the plurality of electrodes and the gas outlet. In some embodiments, the method includes flowing a feed fluid into the processingAttorney Docket No.: ResolHgPCT chamber through the fluid inlet nozzle, and forming a gas product by applying a voltage among the plurality of electrodes.

[0099] In some embodiments, the method further includes, wherein the gas outlet is connected to a gas outlet pipe, and the gas outlet pipe includes a gas outlet temperature sensor, measuring an average operating temperature at the gas outlet temperature sensor of from about 100°C to about 300°C for a temperature measurement duration of 3 minutes. In some embodiments, the method further includes, wherein the gas outlet is connected to a gas outlet pipe, and the gas outlet pipe includes a pressure sensor, measuring an average operating pressure at the pressure sensor of from about 150 kPa to about 8,000 kPa for a pressure measurement duration of 3 minutes. In some embodiments, the voltage is an AC voltage from about 100 V to about 50 kV. In some embodiments, the method further includes combining any of these features mentioned in these embodiments.

[0100] In some embodiments, the feed fluid is a feed liquid, a feed gas, or a feed slurry, or wherein the feed fluid is a hydrocarbon, a methane, a flare gas, a natural gas, a syngas, a biogas, a bioliquid, or a molecule containing a carbon atom and a hydrogen atom, or any mixture thereof. In some embodiments, the gas product includes hydrogen gas. In some embodiments, the method further includes combining any of these features mentioned in these embodiments.

[0101] In some embodiments, the method further includes forming a carbon particle inside the processing chamber by applying the voltage among the plurality of electrodes and collecting the carbon-containing particle by flowing a quench fluid through the quench fluid inlet.

[0102] In some embodiments, the method further includes, wherein the chamber bottom portion includes a bottom valve, and wherein the funnel wall forms a funnel opening above the bottom valve, removing the carbon-containing particle from the processing chamber by opening the valve. In some embodiments, the quenching fluid includes water, an aqueous solution, a water slurry, or any combination thereof. In some embodiments, the method further includes combining any of these features mentioned in these embodiments.

[0103] In some embodiments, the method further includes before flowing a feed fluid into the processing chamber, heating the feed fluid to a temperature of about 300°C to about 800°C.

[0104] In some embodiments, the method further includes, wherein the processing chamber includes a non-feed fluid nozzle, flowing non-feed fluid through the non-feed fluid nozzle, wherein the non-feed fluid includes O2, H2O, CO2, a non-combustible fluid, or a mixture thereof. In some embodiments, the gas product includes hydrogen and carbon monoxide. In some embodiments, the feed fluid includes, or is limited to, a fluid having one or more hydrogen atoms bound to a carbon atom. In some embodiments, the feed fluid excludes any fluid that does not have one or more hydrogen atoms bound to a carbon atom. In some embodiments, a non-feedAttorney Docket No.: ResolHgPCT fluid includes a fluid that excludes a fluid having one or more hydrogen atoms bound to a carbon atom.

[0105] In some embodiments, a production rate of the product gas is from about 1.0 metric tons per day to about 5.0 metric tons per day. In some embodiments, a production rate of the gas product is from about 1.0 metric tons per day to about 1,000.0 metric tons per day.

[0106] Embodiments of a gas product manufacturing system are disclosed. In some embodiments, the gas product manufacturing system includes a processing chamber, wherein the processing chamber includes a feed fluid inlet, a gas outlet, a quench fluid inlet, a chamber bottom portion, and a chamber interior surface, wherein the processing chamber has a plurality of electrodes penetrating the processing chamber. In some embodiments, the chamber bottom portion includes a funnel wall, wherein the funnel wall is positioned below the quench fluid inlet, wherein the funnel wall protrudes from the chamber interior surface toward the chamber bottom portion, and wherein the funnel wall is positioned between the plurality of electrodes and the gas outlet.

[0107] In some embodiments of the gas product manufacturing system, the plurality of electrodes includes from 2 to 20 electrodes. In some embodiments, at least one electrode of the plurality of electrodes includes a graphite material. In some embodiments, at least one electrode of the plurality of electrodes includes a width of about 3.0 cm to about 122.0 cm. In some embodiments, at least one electrode of the plurality of electrodes has an electrode top, an electrode bottom, and an electrode side, and wherein at least a portion of the electrode side is in contact with a ceramic coating layer. In some embodiments, at least one electrode of the plurality of electrodes has an electrode top, an electrode bottom, and an electrode side, and wherein the electrode penetrates into the processing chamber through an electrode seal. In some embodiments, at least one electrode of the plurality of electrodes has an electrode top, an electrode bottom, and an electrode side, and wherein the electrode penetrates into the processing chamber through an electrode seal, wherein the electrode seal includes a ceramic fiber material in contact with the electrode side. In some embodiments, the plurality of electrodes is from 2 to 12 electrodes, and wherein an electrode of the plurality of electrodes has an electrode top, an electrode bottom, and an electrode side, and wherein at least a portion of an electrode side is in contact with a ceramic coating layer, and wherein the electrode penetrates into the processing chamber through an electrode seal, and wherein the electrode seal includes a ceramic fiber material in contact with the ceramic coating layer.

[0108] In some embodiments of the gas product manufacturing system, the feed fluid inlet includes a fluid inlet nozzle that protrudes from the chamber interior surface. In some embodiments, the feed fluid inlet includes from 1 to 20 fluid inlet nozzles. In someAttorney Docket No.: ResolHgPCT embodiments, the fluid inlet nozzle has from 1 to about 30 inlet nozzle openings. In some embodiments, the fluid inlet nozzle protrudes a fluid inlet nozzle longest distance of from about 1.0 cm to about 25.0 cm from the chamber interior surface, wherein the fluid inlet nozzle has from 1 to 30 inlet nozzle openings, and the inlet nozzle openings have an average internal longest distance across the inlet nozzle openings of from about 0.1 cm to about 5.0 cm, and a ratio of fluid inlet nozzle longest distance to the average internal longest distance across the inlet nozzle openings of from 2:1 to 250:1. In some embodiments, the processing chamber has an interior chamber width of from about 30.0 cm to about 460.0 cm, and a ratio of an interior chamber height to the interior chamber width is from about 3:1 to about 12:1. In some embodiments, the fluid inlet nozzle includes a fluid inlet nozzle material, wherein the fluid inlet nozzle material includes a steel alloy, a titanium alloy, or a nickel alloy. In some embodiments, the gas product manufacturing system combines any of these features mentioned in these embodiments.

[0109] In some embodiments of the gas product manufacturing system, the processing chamber includes a heatshield, and at least a portion of the heatshield is positioned between the plurality of electrodes and the fluid inlet nozzle. In some embodiments, the processing chamber includes one or more heatshields, and the feed fluid inlet includes from 1 to 20 fluid inlet nozzles, and at least one portion of one heatshield is located between the plurality of electrodes and one or more of the fluid inlet nozzles.

[0110] In some embodiments of the gas product manufacturing system, the funnel wall forms a funnel opening at a quench fluid level, and wherein the gas outlet is positioned above the quench fluid level.

[0111] In some embodiments of the gas product manufacturing system, the chamber bottom portion includes a bottom valve, and wherein the funnel wall forms a funnel opening above the bottom valve. In some embodiments, the processing chamber includes a heat exchanger beneath or within the chamber interior surface.

[0112] Embodiments of a processing chamber for producing a gas product are disclosed. In some embodiments, the processing chamber a feed fluid inlet, a gas outlet, a quench fluid inlet, a chamber bottom portion, and a chamber interior surface, wherein the processing chamber has a plurality of electrodes penetrating the processing chamber. In some embodiments, the chamber bottom portion includes a funnel wall, wherein the funnel wall is positioned below the quench fluid inlet, wherein the funnel wall protrudes from the chamber interior surface toward the chamber bottom portion, and wherein the funnel wall is positioned between the plurality of electrodes and the gas outlet. In more detail,Attorney Docket No.: ResolHgPCT

[0113] Embodiment 1

[0114] A gas product manufacturing system comprising a processing chamber, wherein the processing chamber includes a feed fluid inlet, a gas outlet, a quench fluid inlet, a chamber bottom portion, and a chamber interior surface, wherein the processing chamber has a plurality of electrodes penetrating the processing chamber, and wherein the chamber bottom portion includes a funnel wall, wherein the funnel wall is positioned below the quench fluid inlet, wherein the funnel wall protrudes from the chamber interior surface toward the chamber bottom portion, and wherein the funnel wall is positioned between the plurality of electrodes and the gas outlet.

[0115] Embodiment 2

[0116] The gas product manufacturing system of embodiment 1 and 3-6, wherein the plurality of electrodes includes from 2 to 20 electrodes, or wherein at least one electrode of the plurality of electrodes includes a graphite material, or wherein at least one electrode of the plurality of electrodes includes a width of about 3.0 cm to about 122.0 cm, or wherein at least one electrode of the plurality of electrodes has an electrode top, an electrode bottom, and an electrode side, and wherein at least a portion of the electrode side is in contact with a ceramic coating layer, or wherein at least one electrode of the plurality of electrodes has an electrode top, an electrode bottom, and an electrode side, and wherein the electrode penetrates into the processing chamber through an electrode seal, or wherein at least one electrode of the plurality of electrodes has an electrode top, an electrode bottom, and an electrode side, and wherein the electrode penetrates into the processing chamber through an electrode seal, wherein the electrode seal includes a ceramic fiber material in contact with the electrode side, or wherein the plurality of electrodes is from 2 to 12 electrodes, and wherein an electrode of the plurality of electrodes has an electrode top, an electrode bottom, and an electrode side, and wherein at least a portion of an electrode side is in contact with a ceramic coating layer, and wherein the electrode penetrates into the processing chamber through an electrode seal, and wherein the electrode seal includes a ceramic fiber material in contact with the ceramic coating layer.

[0117] Embodiment 3

[0118] The gas product manufacturing system of any one of embodiments 1-2 and 4-6, wherein the feed fluid inlet includes a fluid inlet nozzle that protrudes from the chamber interior surface, or wherein the feed fluid inlet includes from 1 to 20 fluid inlet nozzles, or wherein the fluid inlet nozzle has from 1 to about 30 inlet nozzle openings, or wherein the fluid inlet nozzle protrudes a fluid inlet nozzle longest distance of from about 1.0 cm to about 25.0 cm from the chamber interior surface, wherein the fluid inlet nozzle has from 1 to 30 inlet nozzle openings, and the inlet nozzle openings have an average internal longest distance across the inlet nozzleAttorney Docket No.: ResolHgPCT openings of from about 0.1 cm to about 5.0 cm, and a ratio of fluid inlet nozzle longest distance to the average internal longest distance across the inlet nozzle openings of from 2:1 to 250:1, or wherein the processing chamber has an interior chamber width of from about 30.0 cm to about 460.0 cm, and a ratio of an interior chamber height to the interior chamber width is from about 3:1 to about 12:1, or wherein the fluid inlet nozzle includes a fluid inlet nozzle material, wherein the fluid inlet nozzle material includes a steel alloy, a titanium alloy, or a nickel alloy, or any combination thereof.

[0119] Embodiment 4

[0120] The gas product manufacturing system of any one of embodiments 1-3 and 5-6, wherein the processing chamber includes a heatshield, and at least a portion of the heatshield is positioned between the plurality of electrodes and the fluid inlet nozzle, or wherein the processing chamber includes one or more heatshields, and the feed fluid inlet includes from 1 to 20 fluid inlet nozzles, and at least one portion of one heatshield is located between the plurality of electrodes and one or more of the fluid inlet nozzles.

[0121] Embodiment 5

[0122] The gas product manufacturing system of any one of embodiments 1-4 and 6, wherein the funnel wall forms a funnel opening at a quench fluid level, and wherein the gas outlet is positioned above the quench fluid level.

[0123] Embodiment 6

[0124] The gas product manufacturing system of any one of embodiments 1-5, wherein the chamber bottom portion includes a bottom valve, and wherein the funnel wall forms a funnel opening above the bottom valve, or wherein the processing chamber includes a heat exchanger beneath or within the chamber interior surface.

[0125] Embodiment 7

[0126] A processing chamber for producing a gas product, comprising a feed fluid inlet, a gas outlet, a quench fluid inlet, a chamber bottom portion, and a chamber interior surface, wherein the processing chamber has a plurality of electrodes penetrating the processing chamber, and wherein the chamber bottom portion includes a funnel wall, wherein the funnel wall is positioned below the quench fluid inlet, wherein the funnel wall protrudes from the chamber interior surface toward the chamber bottom portion, and wherein the funnel wall is positioned between the plurality of electrodes and the gas outlet.

[0127] Embodiment 8

[0128] A method of producing a gas product comprising, providing a processing chamber, wherein the processing chamber includes having a feed fluid inlet, a gas outlet, a quench fluid inlet, a chamber bottom portion, and a chamber interior surface, wherein the processing chamberAttorney Docket No.: ResolHgPCT has a plurality of electrodes penetrating the processing chamber, and wherein the chamber bottom portion includes a funnel wall, wherein the funnel wall is positioned below the quench fluid inlet, wherein the funnel wall protrudes from the chamber interior surface toward the chamber bottom portion, and wherein the funnel wall is positioned between the plurality of electrodes and the gas outlet, flowing a feed fluid into the processing chamber through the fluid inlet nozzle, and forming a gas product by applying a voltage among the plurality of electrodes.

[0129] Embodiment 9

[0130] The method of any one of embodiments 8 and 10-15, comprising: wherein the gas outlet is connected to a gas outlet pipe, and the gas outlet pipe includes a gas outlet temperature sensor, measuring an average operating temperature at the gas outlet temperature sensor of from about 100°C to about 300°C for a temperature measurement duration of 3 minutes; or wherein the gas outlet is connected to a gas outlet pipe, and the gas outlet pipe includes a gas outlet pressure sensor, measuring an average operating pressure at the pressure sensor of from about 150 kPa to about 8000 kPa for a pressure measurement duration of 3 minutes; wherein chamber temperature sensor is located between the funnel wall and the plurality of electrode, measuring an average operating temperature at the chamber temperature sensor of from about 1,200°C to about 1,800°C for a temperature measurement duration of 3 minutes; wherein the voltage is an alternating current voltage from about 100 V to about 50 kV; or any combination thereof.

[0131] Embodiment 10

[0132] The method of any one of embodiments 8-9 and 11-15, comprising: wherein the feed fluid is a feed liquid, a feed gas, or a feed slurry; or wherein the feed fluid is a hydrocarbon, methane, a flare gas, a natural gas, a syngas, a biogas, a bioliquid, or a molecule containing a carbon atom and a hydrogen atom, or any mixture thereof, or wherein the gas product includes hydrogen gas, or any combination thereof.

[0133] Embodiment 11

[0134] The method of any one of embodiments 8-10 and 12-15, comprising: forming a carbon particle inside the processing chamber by applying the voltage among the plurality of electrodes and collecting the carbon-containing particle by flowing a quench fluid through the quench fluid inlet.

[0135] Embodiment 12

[0136] The method of any one of embodiments 8-11 and 13-15, comprising: wherein the chamber bottom portion includes a bottom valve, and wherein the funnel wall forms a funnel opening above the bottom valve, removing the carbon-containing particle from the processing chamber by opening the valve, or wherein the quenching fluid includes water, an aqueous solution, a water slurry, or any combination thereof, or any combination thereof.Attorney Docket No.: ResolHgPCT

[0137] Embodiment 13

[0138] The method of any one of embodiments 8-12 and 14-15, comprising: before flowing a feed fluid into the processing chamber, heating the feed fluid to a temperature of about 300°C to about 800°C.

[0139] Embodiment 14

[0140] The method of any one of embodiments 8-13 and 15, comprising: wherein the processing chamber includes a non-feed fluid nozzle, flowing non-feed fluid through the non- feed fluid nozzle, wherein the non-feed fluid includes O2, H2O, CO2, a non-combustible fluid, or a mixture thereof, and wherein the gas product includes hydrogen and carbon monoxide.

[0141] Embodiment 15

[0142] The method of any one of embodiments 8-14, wherein a production rate of the product gas is from about 1.0 metric tons per day to about 5.0 metric tons per day, or wherein a production rate of the gas product is from about 1.0 metric tons per day to about 1,000.0 metric tons per day. EXAMPLE

[0143] The reaction processing chamber would be manufactured as shown in the drawings. The material for the electrodes would be graphite or titanium or a titanium alloy. The material for the heat shield can be graphite or titanium or a titanium alloy. The ceramic coating layer can be made of a ceramic paste, such as PYRO-PUTTY®High Temperature Ceramic- Metallic Putties (Beaver, UT) or CRC ceramic paste (Belgium). The ceramic fiber material would be KAOWOOL®(LYNN MANUFACTURING®, Lynn, MA).

Claims

Attorney Docket No.: ResolHgPCT CLAIMS What is claimed is:

1. A gas product manufacturing system comprising: a processing chamber, wherein the processing chamber includes a feed fluid inlet, a gas outlet, a quench fluid inlet, a chamber bottom, and a chamber interior surface, wherein the processing chamber has a plurality of electrodes penetrating the processing chamber, and wherein the chamber bottom includes a funnel wall, wherein the funnel wall is positioned below the quench fluid inlet, wherein the funnel wall protrudes from the chamber interior surface toward the chamber bottom, and wherein the funnel wall is positioned between the plurality of electrodes and the gas outlet.

2. The gas product manufacturing system of claim 1, wherein the plurality of electrodes ^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^ ^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^ ^^^ wherein at least one electrode of the plurality of electrodes includes a width of about 3.0 ^^^^^^^^^^^^^^^^^^^^^^^^ wherein at least one electrode of the plurality of electrodes has an electrode top, an electrode bottom, and an electrode side, and wherein at least a portion of the electrode side is in ^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^ wherein at least one electrode of the plurality of electrodes has an electrode top, an electrode bottom, and an electrode side, and wherein the electrode penetrates into the processing ^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^ wherein at least one electrode of the plurality of electrodes has an electrode top, an electrode bottom, and an electrode side, and wherein the electrode penetrates into the processing chamber through an electrode seal, wherein the electrode seal includes a ceramic fiber material ^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^ wherein the plurality of electrodes is from 2 to 12 electrodes, and wherein an electrode of the plurality of electrodes has an electrode top, an electrode bottom, and an electrode side, and wherein at least a portion of an electrode side is in contact with a ceramic coating layer, and wherein the electrode penetrates into the processing chamber through an electrode seal, and wherein the electrode seal includes a ceramic fiber material in contact with the ceramic coating layer.

3. The gas product manufacturing system of claim 1,Attorney Docket No.: ResolHgPCT wherein the feed fluid inlet includes a fluid inlet nozzle that protrudes from the chamber ^^^^^^^^^^^^^^^^^^^^ ^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^ ^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^ wherein the fluid inlet nozzle protrudes a fluid inlet nozzle longest distance of from about 1.0 cm to about 25.0 cm from the chamber interior surface, wherein the fluid inlet nozzle has from 1 to 30 inlet nozzle openings, and the inlet nozzle openings have an average internal longest distance across the inlet nozzle openings of from about 0.1 to about 5.0 cm, and a ratio of fluid inlet nozzle longest distance to the average internal longest distance across the inlet nozzle ^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^ wherein the processing chamber has an interior chamber width of from about 30.0 cm to about 460.0 cm, and a ratio of an interior chamber height to the interior chamber width is from ^^^^^^^^^^^^^^^^^^^^^^^^^^^^ wherein the fluid inlet nozzle includes a fluid inlet nozzle material, wherein the fluid inlet ^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^ ^^^^^^^^^^^^^ any combination thereof.

4. The gas product manufacturing system of claim 3, wherein the processing chamber includes a heatshield, and at least a portion of the heatshield is positioned between the plurality ^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^ wherein the processing chamber includes one or more heatshields, and the feed fluid inlet includes from 1 to 20 fluid inlet nozzles, and at least one portion of one heatshield is located between the plurality of electrodes and one or more of the fluid inlet nozzles.

5. The gas product manufacturing system of claim 1, wherein the funnel wall forms a funnel opening at a quench fluid level, and wherein the gas outlet is positioned above the quench fluid level.

6. The gas product manufacturing system of claim 1, wherein the chamber bottom includes ^^^^^^^^^!^^!^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^!^^^^^^^^^^^^^!^^!^^^^^ wherein the processing chamber includes a heat exchanger beneath or within the chamber interior surface.

7. A processing chamber for producing a gas product comprising: a feed fluid inlet, a gas outlet, a quench fluid inlet, a chamber bottom, and a chamber interior surface, wherein the processing chamber has a plurality of electrodes penetrating the processing chamber, andAttorney Docket No.: ResolHgPCT wherein the chamber bottom includes a funnel wall, wherein the funnel wall is positioned below the quench fluid inlet, wherein the funnel wall protrudes from the chamber interior surface toward the chamber bottom, and wherein the funnel wall is positioned between the plurality of electrodes and the gas outlet.

8. A method of producing a gas product comprising: providing a processing chamber, wherein the processing chamber includes having a feed fluid inlet, a gas outlet, a quench fluid inlet, a chamber bottom, and a chamber interior surface, wherein the processing chamber has a plurality of electrodes penetrating the processing chamber, and wherein the chamber bottom includes a funnel wall, wherein the funnel wall is positioned below the quench fluid inlet, wherein the funnel wall protrudes from the chamber interior surface toward the chamber bottom, and wherein the funnel wall is positioned between the plurality of electrodes and the gas outlet. ^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^ forming a gas product by applying a voltage among the plurality of electrodes.

9. The method of claim 8, further comprising: wherein the gas outlet is connected to a gas outlet pipe, and the gas outlet pipe includes a gas outlet temperature sensor, measuring an average operating temperature at the gas outlet temperature sensor of from ^^^^^^^^^"#^^^^^^^^^^^^^"#^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^ wherein the gas outlet is connected to a gas outlet pipe, and the gas outlet pipe includes a gas outlet pressure sensor, measuring an average operating pressure at the pressure sensor of from about 150 kPa to about 8,^^^^ $^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^ wherein chamber temperature sensor is located between the funnel wall and the plurality of electrode, measuring an average operating temperature at the chamber temperature sensor of from ^^^^^^^^^^^"#^^^^^^^^^^^^%^^"#^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^ ^^^^^^^^^^^^!^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^!^^^^^^^^^^^^^^^^^^^^^^&^^^^^^^^^^^^^ &^^^^^ any combination thereof.

10. '^^^^^^^^^^^^^^^^^^^%^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^(^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^ or wherein the feed fluid is a hydrocarbon, methane, a flare gas, a natural gas, a syngas, a biogas, a bioliquid, or a molecule containing a carbon atom and a hydrogen atom, or any mixture ^^^^^^^^^^^ ^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^Attorney Docket No.: ResolHgPCT any combination thereof.

11. The method of claim 8, further comprising: forming a carbon particle inside the processing chamber by applying the voltage among ^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^ collecting the carbon-containing particle by flowing a quench fluid through the quench fluid inlet.

12. The method of claim 11, further comprising: wherein the chamber bottom includes a bottom valve, and wherein the funnel wall forms ^^^^^^^^^^^^^^^^^^^^!^^^^^^^^^^^^^!^^!^^^ removing the carbon-containing particle from the processing chamber by opening the !^^!^^^^^ wherein the quenching fluid includes water, an aqueous solution, a water slurry, or any ^^^^^^^^^^^^^^^^^^^^^^^ any combination thereof.

13. The method of claim 8, further comprising: before flowing a feed fluid into the processing chamber, heating the feed fluid to a temperature of about 300°C to about 800°C.

14. The method of claim 8, further comprising: wherein the processing chamber includes a non-feed fluid nozzle, flowing non-feed fluid through the non-feed fluid nozzle, wherein the non-feed fluid includes O2, H2O, CO2, a non-combustible fluid, or a mixture thereof, and wherein the gas product includes hydrogen and carbon monoxide.

15. The method of claim 8, wherein a production rate of the product gas is from about 1.0 ^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^ wherein a production rate of the gas product is from about 1.0 metric tons per day to about 1,000.0 metric tons per day.

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