Thermal decomposition of polyfluoroalkyl substances, fluorochemicals, and other halocarbons

Abstract

An example method includes introducing feedstock into a high temperature reactor. The feedstock includes or at least is suspected to include one or more halocarbons. The method may also include converting at least a portion of the one or more halocarbons into at least one hydrohalic acid (e.g., molecules exhibiting the form HX). The method includes recovering one or more products from the high temperature reactor. The products include at least one hydrohalic acid.

Description

THERMAL DECOMPOSITION OF POLYFLUOROALKYL SUBSTANCES, FLUOROCHEMICALS, AND OTHER HALOCARBONSCROSS-REFERENCE TO RELATED APPLICATION(S)

[0001] This applications claims priority to U.S. Provisional Patent Application No. 63 / 568,387 filed on March 21, 2024, the disclosure of which is incorporated herein, in its entirety, by this reference.BACKGROUND

[0002] In order to combat the destruction of the ozone layer, 46 signatories agreed to phase out ozone depleting chemicals. The agreement was signed in 1987 in Montreal and became known as the Montreal protocol, eventually signed by 198 nations. The protocol successfully reversed the degradation of the ozone layer mostly by phasing out chlorofluorocarbons used in refrigerants and blowing agents such as R-12, R-113, R13, and R11, and replacing them with hydrofluorocarbons and hydrochlorofluorocarbons such as R- 134a, R-22, and a variety of blends. However, most of these new refrigerants have a high global warming potential, up to thousands of times more potent than CO2. Consequently, many of these refrigerants are also now being phased out, and the inventories of these chemicals must be destroyed.

[0003] Additionally, another family of fluorochemicals, polyfluoroalkyl substances (“PF AS'’) including perfluorooctane sulfonic acid (“PFOs”) and perfluorooctanoic acids (“PFOAs”) have been discovered to be hazardous and do not decompose in a timely manner (so called “forever chemicals”). Inventories of these chemicals must also be destroyed. The government is now seeking processes that can destroy these chemicals with 99.99999% efficiency. Similar challenges exist for chlorinated hydrocarbons such as PCBs (polychlorinated biphenyls) which also present a public health hazard and must be destroyed.

[0004] All of these chemicals can be broadly classified as “halocarbons.” Halocarbons can get into drinking water. Often the first line of defense in drinking water to remove these chemicals is sorption either through ion exchange or activated carbon. However, these materials that have trapped the halocarbon must have the halocarbons destroyed to either be reused, or safely disposed of. Removal of the halocarbon is difficult. Destruction efficiencies on granulated activated carbon (GAC) of up to 99.999% have been reported, but thistechnology creates residue “daughter fluorocarbons'’ which also have severe toxicity and themselves are “forever chemicals.”SUMMARY

[0005] Embodiments disclosed herein include methods to at least partially decompose one or more halocarbons and systems configured to perform the method. In an embodiment, a method to at least partially decompose one or more halocarbons is disclosed. The method includes introducing feedstock into a high temperature reactor. The feedstock includes or is suspected to include the one or more halocarbons. The method also includes converting at least a portion of the one or more halocarbons into at least one hydrohalic acid. The method further includes recovering one or more products from the high temperature reactor. The one or more products includes the at least one hydrohalic acid.

[0006] The one or more halocarbons may include one or more carbon containing molecules of the form CmHnOpXqYr, where X denotes a halogen, Y denotes at least one other heteroatom, wherein m and q are greater than 0, and n, p, or r are greater than or equal to 0.

[0007] In an embodiment, a system to at least partially decompose one or more halocarbons is disclosed. The system includes a processing chamber at least defining an interior region, a feedstock input, and a product output. The system further includes a feedstock source configured to provide feedstock to the interior region via the feedstock input. The feedstock includes or is suspected to include the one or more halocarbons. The system also includes one or more heating elements configured to heat at least the interior region. The system is configured to convert at least a portion of the one or more halocarbons into at least one hydrohalic acid and recover one or more products via the product output.

[0008] In an embodiment, a method to at least partially decompose one or more halocarbons is disclosed. The method includes introducing feedstock into ahigh temperature reactor. The feedstock includes or is suspected to include the one or more halocarbons. The method also includes introducing excess hydrogen from a hydrogen source into the high temperature reactor such that a molar ratio of hydrogen to halogen (moles hydrogen / moles halogen) is greater than 1.0. The method further includes converting substantially all of the one or more halocarbons into at least one hydrohalic acid. Additionally, the method includes recovering one or more products from the high temperature reactor. The one or more products includes the at least one hydrohalic acid. At least 99.99% of the one or more halocarbons are decomposed during the method.

[0009] In an embodiment, a method to at least partially decompose one or more halocarbons to produce one or more of hydrohalic acids or carbon materials is disclosed. The method includes introducing feedstock into a high temperature reactor, the feedstock including sorbed carbon material having or suspected to have the one or more halocarbons absorbed thereon. The method also includes converting at least a portion of the one or more halocarbons into at least one hydrohalic acid. The method further includes producing pure carbon material that does not include the one or more halocarbons absorbed thereon. The method additionally includes recovering one or more products from the high temperature reactor. The one or more products includes the at least one hydrohalic acid and the pure carbon material.BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The drawings illustrate several embodiments of the present disclosure, wherein identical reference numerals refer to identical or similar elements or features in different views or embodiments shown in the drawings.

[0011] FIG. 1 is a flow chart of an example method to at least partially decompose one or more halocarbons, according to an embodiment.

[0012] FIG. 2 is a cross-sectional schematic of a system that may be used to at least partially decompose one or more halocarbons, according to an embodiment.

[0013] FIG. 3 is a schematic of a system, according to an embodiment.

[0014] FIG. 4 is a schematic of a system, according to an embodiment.

[0015] FIG. 5 is a schematic of a system that is configured to decompose one or more halocarbons, according to an embodiment.DETAILED DESCRIPTION

[0016] Embodiments disclosed herein include methods to at least partially decompose one or more halocarbons and systems configured to perform the method. An example method includes introducing feedstock into a high temperature reactor. The feedstock includes, or at least is suspected to include one or more halocarbons. The method may also include converting at least a portion of the one or more halocarbons into at least one hydrohalic acid (e.g., molecules exhibiting the form HX). The method includes recoveringone or more products from the high temperature reactor. The products include at least one hydrohalic acid.

[0017] The method may be performed in a high temperature reactor configured to at least partially decompose the halocarbons. The high temperature reactor includes a processing chamber defining at least an interior region, a feedstock input, and a product output. The high temperature reactor also includes a feedstock source configured to provide, either directly or indirectly (e.g. via a gasifier), feedstock to the interior region. The high temperature reactor also includes one or more heating elements, such as at least one plasma electrode or joule heating electrode, configured to heat at least the interior region. The high temperature reactor is configured to convert at least some of the halocarbons present in the feedstock to at least one hydrohalic acid. The high temperature reactor is also configured to recover one or more products from the processing chamber, wherein the products include the hydrohalic acid.

[0018] The methods and systems (e.g., high temperature reactors) disclosed herein are an improvement over conventional methods and systems that are configured to at least partially decompose halocarbons. For example, the methods and systems disclosed herein are capable to decomposing or otherwise destroying substantially all of the halocarbons. In particular, the methods and systems disclosed herein are surprisingly able to decompose at least 99.99%, at least 99.999%, at least 99.9999% or at least 99.99999% of the halocarbons while preventing or at least inhibiting the formation of so called “daughter fluorocarbons.” The destruction and removal efficiencies described herein are provided as a percentage that represents the number of molecules of a compound removed or destroyed relative to the number of molecules that entered the system.

[0019] As used herein, “halocarbons” is interpreted to mean one or more carbon containing molecules of the form CmHnOpXqYr, where X denotes a halogen and Y denotes at least one other heteroatom, wherein m and q are greater than 0, and n, p, or r are greater than or equal to 0. Common halogens in halocarbons include F, Cl, or Br. Common heteroatoms included in the halocarbons includes S or N. Non-limiting examples of halocarbons may include at least one of a) one or more of fluorocarbons, hydrofluorocarbons, chlorofluorocarbons (e g., Freon®), hydrofluorocarbons, often ozonedepleting and / or greenhouse gases; b) brominated hydrocarbons and substituted brominated versions of a) (e.g., Halon®); or c) polychlorinated biphenyls (PCBs).

[0020] As used herein, the term “decompose” or the like (e.g., decomposition) is interpreted to mean destroying, breaking apart, severing bonds, or otherwise chemicallybreaking down a compound. As used herein, the term “convert'’ or the like (e.g, converting, conversion, etc.) is interpreted to mean synthesizing of one or more new compounds, for example, by forming bonds or otherwise converting one chemical (e.g, halocarbon) into a new chemical (e.g, hydrohalic acid). It is noted that, often, the process of decomposing one or more chemicals and converting the chemicals are performed contemporaneously, such as simultaneously or substantially simultaneously. As such, depending on context, the terms decompose and convert may be carried out simultaneously or substantially simultaneously.

[0021] FIG. 1 is a flow chart of an example method 100 to at least partially decompose one or more halocarbons, according to an embodiment. The example method 100 may include one or more operations, functions, or actions as illustrated by one or more of blocks 105. 110, and 115. The example method 100 may begin with block 105, which recites “introducing feedstock into a high temperature reactor, the feedstock including or suspected to include one or more halocarbons.” After block 105, the example method may include block 110, which recites “converting at least a portion of the one or more halocarbons into at least one hydrohalic acid.” After block 110, the example method may include block 115, which recites “recovering one or more products from the high temperature reactor, the one or more products including the at least one hydrohalic acid.” Blocks 105, 110, and 115 are provided for illustrative purposes. In some embodiments, at least one of the blocks of may be performed in a different order, one or more blocks may be eliminated, one or more blocks may be divided into two or more blocks, one or more blocks may be combined, or one or more blocks may be supplemented. The actions described in blocks 105, 110, and 1 15 may be performed responsive to instructions from a controller (e.g, controller 240 of FIG. 2). The method 100 may also be viewed as a method of forming one or more hydrohalic acids from one or more halocarbons.

[0022] Block 105 includes “introducing feedstock into a high temperature reactor, the feedstock including or suspected to include one or more halocarbons.” As will be discussed in more detail with regards to FIGS. 2-4, the high temperature reactor may include a processing chamber defining an interior region. The high temperature reactor also be or include a feedstock source configured to hold feedstock therein and the processing chamber defines a feedstock inlet. The feedstock source is coupled to the feedstock inlet and is configured to provide the feedstock to the interior region of the processing chamber.

[0023] The high temperature reactor and / or processing chamber may include one or more high temperature reactors and / or processing chambers. For example, the high temperature reactor may include one or more of a gasifier, a plasma enhanced melter, athermal residence chamber, or a baghouse. Each high temperature reactor may include a separate processing chamber, through which the feedstock may processed in series. In an example, the high temperature reactor may include only a plasma enhanced melter, a plasma enhanced melter in combination with a thermal residence chamber, a plasma enhanced melter in combination with a gasifier, a plasma enhanced melter in combination with a gasifier and a thermal residence chamber, or the like.

[0024] The feedstock may include a material that includes, or is otherwise suspected to include, one or more halocarbons. Examples of halocarbons that may be included in the feedstock include per- and polyfluoroalkyl substances (e.g., perfluorooctane sulfonic acid or perfluorooctanoic acids), perfluorochemicals, other fluorocarbons, other hydrofluorocarbons, other fluorochemicals, chlorinated hydrocarbons or other chlorofluorocarbons (e.g., polychlorinated biphenyls), chlorofluorochemicals, brominated hydrocarbons, halogenated dioxins, halogenated furan, halogenated polycyclic aromatic hydrocarbons, halogenated biphenyls, brominated flame retardants, polyvinyl chloride- containing plastics, any other halocarbon, or combinations of any of the foregoing. In an example, the feedstock may include substantially pure or high concentrates of halocarbons, such as when the feedstock comes from industrial inventories of halocarbons. In an example, the feedstock may be absorbed on another material, such as granulated activated carbon or other carbon-based material used to remove halocarbons from drinking water. As used herein, for brevity, absorbed and the like (e.g., absorption) refers to both absorption and adsorption. Absorbing the halocarbons on another material may make handling and moving the halocarbons safer and decrease the likelihood of the halocarbons being released into the environment before being received in the processing chamber. In an example, the feedstock may include at least one of municipal solid waste, industrial waste, biomass, coal, natural gas, or any other material that includes or is suspected to include halocarbons. In an example, the feedstock may include one or more liquid components, such as industrial process or cleaning fluids containing one ore more halocarbons therein. Such industrial process or cleaning fluids may be provided from a micro-chip production facility. In an example, the feedstock may include waste electrical and electronic equipment. In an example, the feedstock may include industrial waste such as waste plastics (e.g., PVC conduits, PTFE linings, or the like. In an example, the feedstock may include aqueous film-forming foam, such as a PFAS containing firefighting foam. In an example, the feedstock may include one or more solvents (e.g, acid) that may have one or more portions of the feedstock (e.g., halocarbons) dissolved therein. In an example, the feedstock may include one or more glassparticles for forming a molten glass bath in the processing chamber (e.g., molten material 236), such as borosilicate glass beads.

[0025] In an example, the halocarbons may form or be suspected to form about 10 parts per billion (“ppb”) or more of the feedstock, such as in ranges of about 10 ppb to 100 ppb, about 50 ppb to about 500 ppb, about 100 ppb to about 1 parts per million (“ppm”), about 500 ppb to about 5 ppm, about 1 ppm to about 10 ppm, about 5 ppm to about 20 ppm, about 10 ppm to about 30 ppm. about 25 ppm to about 50 ppm. about 40 ppm to about 70 ppm. about 60 ppm to about 100 ppm about 90 ppm to about 140 ppm, about 130 ppm to about 190 ppm, about 180 ppm to about 250 ppm, about 240 ppm to about 320 ppm, about 310 ppm to about 400 ppm, about 350 ppm to about 500 ppm, about 400 ppm to about 600 ppm, about 500 ppm to about 750 ppm. about 700 ppm to about 1 parts per thousand (“ppt”), about 900 ppm to about 2 ppt, about 1 ppt to about 3 ppt, about 2 ppt to about 4 ppt, about 3 ppt to about 5 ppt, about 4 ppt to about 7 ppt, about 6 ppt to about 10 ppt, about 8 ppt to about 15 ppt, about 10 ppt to about 20 ppt, about 15 ppt to about 30 ppt, about 25 ppt to about 50 ppt, about 40 ppt to about 70 ppt, about 60 ppt to about 100 ppt, about 80 ppt to about 150 ppt, about 100 ppt to about 200 ppt, or about 200 ppt or greater.

[0026] In an embodiment, block 105 may include continuously introducing the feedstock into the processing chamber. Continuously providing the feedstock into the processing chamber may allow the decomposition of the halocarbons and the conversion of the halocarbons into the hydrohalic acids to be performed continuously and for the products to be continuously recovered. However, continuously introducing the feedstock into the processing chamber may cause several issues, namely, the time it takes to heat the feedstock to a sufficiently high temperature for the decomposition of the halocarbons to occur. For example, when the processing chamber includes a molten material (e.g, the high temperature reactor is a molten glass melter, as shown in FIG. 2), the feedstock that is introduced into the processing chamber may form a cold cap on the molten material. The cold cap may have an interface with the molten material where the cold cap is melted into the molten material and / or heat from the molten material is conducted into the cold cap, both of which may cause the decomposition and conversion of the halocarbons to hydrohalic acid(s). The primary mode of thermal energy transfer into the cold cap is conduction from the molten material below the cold cap. This conduction is the rate limiting step in the decomposition and conversion of the halocarbons. As such, the rate that the feedstock is continuously provided into the processing chamber may be less than the conduction from the molten material into the cold cap can decompose and convert the halocarbons. Thetemperature in the processing chamber may be controlled by controlling the feed rate of the feedstock into the processing chamber. The control of the feed rate may accomplished using one or more temperature probes in the processing chamber to ensure a selected temperature is maintained therein based on the feed rate. A controller may automatically adjust the feed rate up or down based on the temperature within the processing chamber. Such temperature changes may also be made based on the type of feedstock.

[0027] Introducing the feedstock into the processing chamber also decreases the thermal energy in the processing chamber. As such, continuously introducing the feedstock into the processing chamber continuously decreases the thermal energy in processing chamber. In such instances, continuously heating the processing chamber may be carried out. but may exceed the ability to maintain constant temperature or supply requisite heating for thermal decomposition in the high temperature reactor.

[0028] In an embodiment, block 105 may include introducing the feedstock into the processing chamber in distinct batches. For example, the block 105 may include introducing a first batch of the feedstock into the processing chamber. After introducing the first batch, block 105 may not include introducing a second batch of the feedstock into the processing chamber until all or at least a selected percentage (e g., at least 80%) of the feedstock is decomposed or converted. Introducing the feedstock into the processing chamber in batches may cause the decomposition and conversion of the halocarbon and the recovery of the products to also occur in batches or at least fluctuate. However, providing the feedstock to the processing chamber in batches may facilitate heating of the processing chamber by allowing the temperature to be increased after introducing the first batch into the processing chamber and before introducing the second batch into the processing chamber (e.g., while decomposing and converting the halocarbons of the first batch).

[0029] The processing chamber and, more particularly the interior region of the processing chamber or one or more elements disposed in the interior region (e.g., the molten material), may exhibit a temperature of about 800 °C to about 3500 °C, such as in ranges of about 800 °C to about 1750 °C, about 1000 °C to about 1300 °C, about 1200 °C to about 1500 °C, about 1400 °C to about 1700 °C, about 1600 °C to about 1900 °C. about 1900 °C to about 2300 °C, about 2200 °C to about 2500 °C, about 2400 °C to about 2700 °C, about 2600 °C to about 3000 °C, about 2750 °C to about 3500 °C, about 1000 °C to about 3000 °C, less than about 3000 °C, less than about 200°C, or more than about 1500 °C . When exposed to such temperatures, the halocarbons present in the processing chamber may decompose and convert to hydrohalic acid(s). For example, the halocarbons may be at leastpartially gasified to form molecular hydrogen, carbon monoxide, and carbon dioxide. During the heating the halocarbons may shed their hydrogen molecules from a carbon backbone, may lose their halogens from the carbon backbone, and may lose the heteroatoms from the carbon backbone. The carbon backbone itself may break into smaller parts to form one or more carbon containing species, such as carbon dioxide, carbon monoxide, carbon black, turbostratic carbon, graphitic carbon, or the like. As the halogens are removed from the halocarbons and exposed to hydrogen at the high temperatures noted above, the thermodynamically favored hydrohalic acid(s) may form between the hydrogen and the halogens.

[0030] The temperature of the processing chamber may be selected for a variety of reasons. In an example, the temperature of the processing chamber may be selected to be high enough to cause the halocarbon to decompose and convert at least into hydrohalic acid. It is noted that this temperature may vary depending on the halocarbon and the halogen present in the halocarbon. In an example, the temperature of the pressing chamber may be selected to be high enough to cause the decomposition and possible conversion (to hydrohalic acid) of the remainder of the feedstock which, again, depends on the composition of the feedstock. In an example, the temperature of the processing chamber may be selected to cause certain chemical reactions to be preferred. For instance, it may be beneficial for most of the halogen of the halocarbon to form the hydrohalic acid. In such an instance, the temperature of the processing chamber may be selected such that the formation of the hydrohalic acid is thermodynamically and otherwise chemically preferred over other possible halogen-containing compounds (<?.g., acids exhibiting the general formula HOX). The temperature of the processing chamber that causes the formation of hydrohalic acids to be preferred may depend on the halogen of the halocarbon and what other possible chemical reactions may occur.

[0031] In an example, the temperature of the processing chamber may be selected based on the other products desired to be formed. For instance, the temperature of the processing chamber may be selected to cause the formation of specific types of carbon. Examples of types of carbon material formed may include amorphous carbon, turbostratic carbon, and graphitic carbon. The temperature of the processing chamber that forms one or more of the different types of carbon (material) may vary, for instance, based on the conditions within the processing chamber. In an embodiment, the processing chamber may convert a majority of the carbon therein into amorphous carbon when the temperature of the processing chamber is about 1100 °K to about 1500 °K, turbostratic carbon when the temperature ofthe processing chamber is about 1500 °K to about 2000 °K, or graphitic carbon when the temperature of the processing chamber is about 2000 °K or greater. In an embodiment, amorphous carbon, turbostratic carbon, and / or graphitic carbon may be formed at lower temperatures than those listed above. It is noted that it may be difficult to only form one ty pe of carbon in the processing chamber. For example, the processing chamber may form at least one of amorphous carbon or turbostratic carbon even when the temperature within the processing chamber is greater than 2000 °K. though at such temperature a majority of the carbon formed in the processing chamber may be graphitic carbon. It should be understood that any of these carbon allotropes (e.g., carbon materials) may be formed as byproducts from the thermal destruction of halocarbons by the techniques and systems disclosed herein.

[0032] Generally, the pressure within the processing chamber is maintained at or near standard atmospheric pressure (e.g., about 1 atm, at least 0.8 atm, less than 1.2 atm, or about 0.8 atm to about 1.2 atm). That said, in some embodiments, the pressure within the processing chamber may be increased (e.g., up to 2 atm) or decreased to facilitate decomposition of the halocarbons and / or the rest of the feedstock and the conversion of the halocarbons into the hydrohalic acids. The pressure within the processing chamber may be controlled using any suitable technique, such as by increasing the flow of the feedstock or the hydrogen from the hydrogen source into the processing chamber or limiting flow of materials through the outlets of the processing chamber. In an embodiment, the pressure within the processing chamber may be less than 1 atm to provide an active suction to the processing chamber to facilitate removal of any gaseous products from the processing chamber. It is noted which chemical reactions occur may depend on the pressure of the processing chamber and, thus, the pressure of the processing chamber may be controlled to make certain, desired chemical reactions (e.g., conversion of halocarbons to hydrohalic acid) preferred.

[0033] Introducing the feedstock including the halocarbon into the processing chamber during block 105 may cause block 110 to occur. Block 110 includes “‘converting at least a portion of the one or more halocarbons into at least one hydrohalic acid.” For example, introducing the feedstock into the heated processing chamber causes the halocarbon to begin to decompose. No wishing to be bound by theory7, the decomposition of the halocarbon may include at least one of breaking the bonds that attach the halogen of the halocarbons to the rest of the molecule, break other bonds of the halocarbon to form intermediate halogencontaining compounds, or otherwise cause the halogen atoms of the halocarbon to be readyand able to leave the halocarbon. There may be hydrogen present in the processing chamber because of at least one of excess hydrogen being provided into the processing chamber, hydrogen formed by the decomposition halogen, or hydrogen formed by the decomposition of the remainder of the feedstock. The halogen of the halocarbon may react with the hydrogen in the processing chamber to form the hydrohalic acid. In other words, introducing the feedstock into the processing chamber causes the halocarbons to convert into hydrohalic acid. It is noted that the hydrogen present may provide reducing conditions during block 110. During block 110, the processing chamber may or may not contain seed material to assist this reaction.

[0034] In a preferred embodiment, substantially all of the halogens in the halocarbons form hydrohalic acids because thermodynamics favor hydrogen scavenging of halogens over fragmentation to other halocarbons at high temperatures, as long as the overall stoichiometry of the feed provides a molar ratio of hydrogen to halogen that is greater than 1.0, it can be expected that the halogens will be consumed by hydrogen to form HX instead of daughter halocarbons. In such an embodiment, 90% or more (e.g, 95% or more, 99% or more, 99.99% or more, 99.999% or more, 99.9999% or more, 99.99999% or more, or 99.999999% or more) of the halogens in the halocarbons form hydrohalic acids. It may be desirable for the halogens in the halocarbons to predominately form hydrohalic acids since the hydrohalic acids have many industrial applications which would reduce demand for fresh hydrohalic acids and the associated environmental and societal impacts of fresh hydrohalic acids’ production, including the carbon footprint and the by-products of the fresh hydrohalic acids production. Further, hydrohalic acids can be easily separated (in high punty) from other products formed within the processing chamber using known and conventional separation techniques. Based on the conversion, nearly all of the halocarbons may be recycled into relatively safe forms of the components therein.

[0035] In an embodiment, not substantially all of the halogens in the halocarbons may form hydrohalic acids. In such an embodiment, the percentage of the halogens in the halocarbons that form hydrohalic acids may be about 1% to about 89%, such as in ranges of about 1% to about 20%, about 10% to about 30%. about 20% to about 40%, about 30% to about 50%, about 40% to about 60%, to about 50% to about 70%, about 60% to about 80%, or about 70% to about 89%. The percent of the halocarbons that form hydrohalic acids may be selected by controlling the conditions within the processing chamber. For example, as previously discussed, the temperature and pressure within the processing chamber may be controlled to ensure that the conversion of halocarbons to hydrohalic acids isthermodynamically and otherwise chemically preferred. The percentage of the halocarbons that form hydrohalic acids may also be controlled based on the other chemicals that are present in the processing chamber that may react with the halogens (e.g., the amount of hydrogen in the processing chamber). In such examples, any unreacted halocarbons, halogens, or other products may be recycled by feeding into the processing chamber again to increase the conversion rate of the halogens to hydrohalic acids.

[0036] In a particular embodiment, block 110 converts the halocarbons into hydrohalic acids or other halogen-containing substantially without forming one or more new halocarbons that are considered forever chemicals, ozone-depleting gases, toxins, or greenhouse gases.

[0037] In an embodiment, the halogens in the halocarbons may form one or more halogen-containing compounds other than or in addition to hydrohalic acids. Examples of such halogen-containing compounds include X2 (e.g., chlorine gas), halogen-containing acids (e.g., HOX), and other halogen- and carbon-containing compounds. Generally, it is desirable that the percent of the halogens that form these other halogen-containing compounds is less than 10%, such as less than 5%, less than 1%, less than 0.1%, and less than 0.01% to maximize the formation of hydrohalic acids that may be easily separated from the other products generated during the method 100. That said, in some embodiments, the percentage of the halogens in the halocarbons that form these other halogen-containing compounds may be greater than 10%, such as greater than about 25% or greater than about 50%. The percent of the halocarbons that form these other halogen-containing compounds may be selected by controlling the conditions within the processing chamber.

[0038] Block 110 may form one or more products other than the hydrohalic acids and other halogen-containing compounds. These products may be formed from the decomposition of the halocarbons, from the remainder of the feedstock, or from another source material. In an example, block 110 may form synthesis gas (“syngas”), which include a mixture of hydrogen and carbon monoxide. Syngas obtained during the method 100 may be used as a fuel to provide heat to the processing chamber or provide electrical energy (e.g. , the syngas is burned using an electrical generator) that powers one or more heating elements of the system. The syngas obtained during use of the system may be used to generate methanol, acetic acid, lubricants, ammonia, fertilizer, or one or more polymers. In an example, block 110 may form one or more hydrogen-containing compounds, such as hydrogen gas (H2), water (H2O, such as steam), methane (CH4), other alkanes, or other hydrogen-containing compounds. As will be discussed in more detail below, the hydrogenis provided to the processing chamber to facilitate converting the halocarbon into hydrohalic acid. As such, the hydrogen-containing compounds formed during block 110 may remain in the processing chamber to facilitate conversion of the halocarbons. If the hydrogencontaining compounds are removed from the processing chamber, the hydrogen-containing compounds may be used to form syngas or may be separated from the products. The hydrogen-containing compounds that are separated from the products may be provided to a hydrogen source or may be flowed back into the processing chamber. In an example, block 110 may form other gaseous products other than the gaseous products disclosed above. Examples of such gaseous products include carbon dioxide.

[0039] In an example, block 110 may form one or more solid products. As used herein, solid products refer to materials that are in a solid state when at the temperature and pressure of the processing chamber. Examples of the solid products include carbon. The carbon may include, for example, amorphous carbon, turbostratic carbon, graphitic carbon, or activated carbon. Which carbon material is obtained from the system may be determined, in part, on the temperature within the processing chamber. For instance, as previously discussed and depending on the conditions within the processing chamber, the method 100 may produce one or more of amorphous carbon if the temperature in the processing chamber is about 1100 °K (about 827 °C) to about 1500 °K (about 1227 °C), turbostratic carbon if the temperature in the processing chamber is about 1500 °K to about 2000 °K (e.g., about 1727 °C), or graphitic carbon if the temperature in the processing chamber is about 2000 °K or greater. That said, the method 100 may produce one or more carbon materials such as amorphous carbon, turbostratic carbon, or graphitic carbon at different temperatures (e.g, lower temperatures than those listed above) depending on the conditions within the processing chamber. The carbon material formed during block 110 may include activated carbon, carbon material used as activated carbon, or carbon that is further processed to form activated carbon. When the carbon material does not include, or only includes negligible amounts (e.g., less than 1 wt% or less than 0. 1 wt%) of, halogens or other impurities therein (e.g., adsorbed or bonded to), the carbon material is referred to as pure carbon material herein. The pure carbon material produced during block 110 may be used, for example, to absorb the halocarbons before the halocarbons are introduced into the processing chamber during block 105 (i.e., the feedstock introduced during block 105 includes halocarbons absorbed on the carbon) to form sorbed carbon (e.g., carbon material having halocarbons, halogens, or hydrohalic acids absorbed thereon). In a particular example, the pure carbon material produced during block 1 10 may be used in a water purification process to removehalocarbons or metals from the drinking water by absorbing the halocarbons or metals. The sorbed carbon including the absorbed (e.g., adsorbed) halocarbons may then be provided back to the processing chamber to decompose and convert the halocarbons. The pure carbon material formed during block 110 may be formed from carbon within the feedstock, such as when the feedstock includes carbon-containing materials (e.g., biomass, polymers) or halocarbons absorbed on pure carbon material (e.g., sorbed carbon material). The carbon material formed dunng block 110 (e.g.. pure carbon material) may be formed from cofeeding (e.g, from a supplemental carbon source, not shown) supplemental natural gas, supplemental feedstock (e.g, biomass, activated carbon) that does not include or is not suspected to include non-negligible quantities of halocarbons, or other supplemental carbon- containing materials.

[0040] Block 110 may include providing hydrogen to the processing chamber. For example, as previously discussed, block 110 includes converting the halogen of the halocarbon into a hydrohalic acid. To facilitate such conversion, the processing chamber needs to have hydrogen present therein to bond with the halogen and form the hydrohalic acid. Without wishing to be bound by any theory or explanation, it is believed that the hydrogen present in the processing chamber scavenges the halogens from the halocarbon to form the hydrohalic acid. To ensure that the halogen of the halocarbon forms hydrohalic acid, the interior region of the processing chamber needs to have equal or greater moles of hydrogen than moles of halogen. That is. the molar ratio of hydrogen to halogen (moles of hydrogen divided by moles of halogen) needs to be equal to or greater than one. If the molar ratio of hydrogen to halogen is less than one, there is not enough hydrogen in the processing chamber to convert substantially all of the halogens of the halocarbon into hydrohalic acid and, instead, the halogens of the halocarbons may form other halogen-containing compounds, such as a halogen gas (e.g.. Ch) or a compound exhibiting a carbon-halogen bond. These halogen-containing compounds may at least one of be less economical, have less industrial uses, or be harder to remove from the gaseous products than the hydrohalic acid. Further, these halogen-containing compounds may also need to be decomposed to prevent ecological and health issues associated with these halogen-containing compounds. That said, in some embodiments, in may be desirable to form these other halogen-containing compounds. It is noted that some halogen compounds (e.g., Ch, Br . and h) may form as reactive intermediate compounds that may, at elevated temperatures, react with steam (e.g., water in its gaseous form) or other hydrogen-containing compounds to form hydrohalic acids.

[0041] As such, block 110 may include providing sufficient hydrogen such that the molar ratio of hydrogen to halogen in the processing chamber is equal to or greater than one, such as about 1.5 or greater, about 2 or greater, about 2.5 or greater, about 3 or greater, about 4 or greater, about 5 or greater, about 7.5 or greater, about 10 or greater, or in ranges of about 1-2, about 1.5-2.5, about 2-4, about 2.5-5, about 4-7.5, or about 5-10. It is noted that increasing the molar ratio of hydrogen to halogen generally decreases the time required to convert the halocarbons into hydrohalic acids and better ensures that substantially all of the halogen of the halocarbon forms hydrohalic acids since halogen does not need to hunt for hydrogen to bond. Also, increasing the molar ratio of hydrogen to halogen decreases the likelihood that a sudden increase of halocarbons in the interior region (e.g, caused by incorrectly calculating or measuring the concentration of halocarbons in the feedstock or by localized portions of the feedstock having higher than average concentrations of the halocarbon) results in failure to convert substantially all of the halogens into hydrohalic acids. That said, in some embodiments, the molar ratio of hydrogen to halogen may be selected to be less than one to form halogen-containing compounds other than or in addition to hydrohalic acid.

[0042] Block 110 may provide hydrogen to the processing chamber using any suitable technique. In an example, the decomposition of the feedstock, by itself, provides sufficient hydrogen to the processing chamber that the molar ratio of hydrogen to halogen is equal to or greater than 1 or that the molar ratio of hydrogen to halogen exhibits any of the other values disclosed herein to ensure that sufficient percentage of the halogens of the halocarbon forms a hydrohalic acid. In an example, the decomposition of the feedstock is not, by itself, a sufficient source of hydrogen to ensure that sufficient percentage of the halogens of the halocarbon forms a hydrohalic acid. In such an example, block 110 may include providing excess hydrogen to the processing chamber. The excess hydrogen may be provided by a hydrogen source that is in fluid communication with the processing chamber. The hydrogen source may store a hydrogen-containing compound therein and may provide the hydrogencontaining compound to the processing chamber, as needed. The excess hydrogen may also be provided from hydrogen-containing compounds that were removed from the processing chamber. Such hydrogen-containing compounds may be separated from the other products removed from the processing chamber. It is noted that the excess hydrogen provided to the processing chamber may include hydrogen gas, water (e.g., steam), methane or other alkane(s), or any other hydrogen source.

[0043] The products produced during block 110 may be controlled based on the materials provided to the processing chamber. For example, block 110 may form hydrohalic acids, syngas, or methane when the interior region of the processing chamber is substantially free of oxygen. In such an example, any excess hydrogen provided to the processing chamber may be substantially free of oxygen (e.g., the excess hydrogen is a non-water hydrogen-containing compound) and / or the feedstock is dried before being introduced into the processing chamber. One or more inert gases may also be provided to the interior region of the processing chamber to maintain the interior region as a desired pressure (e.g. , 0.8 atm to 1.2 atm). In an example, the block 110 may include providing oxygen in the processing chamber. The oxygen in the processing chamber may vary the products produced during block 110 than if the processing chamber does not include oxygen. For instance, the oxygen in the processing chamber may vary the ratio of hydrogen to carbon monoxide produced during block 110 compared to the processing chamber that does not include oxygen.

[0044] In an embodiment, block 110 may decompose substantially all of the halocarbons present in the feedstock. Substantially all of the halocarbons are decomposed when, after block 110, the halocarbons form at most 100 ppb, more preferably at most 10 ppb, or even more preferably at most 1 ppb of the products recovered from the processing chamber.

[0045] Block 115 includes “recovering one or more products from the high temperature reactor, the one or more products including the at least one hydrohalic acid / ’ The products recovered during block 1 1 may include any of the products formed during block 1 10, as discussed above. For example, block 115 may include recovering one or more hydrohalic acids, one or more other halogen-containing compounds, syngas, carbon dioxide, one or more alkanes, water, other hydrogen-containing compounds, carbon, or any other suitable product. The products recovered during block 1 15 may include one or more gaseous products (i.e. , products that are gaseous when in the processing chamber) and / or one or more solid products.

[0046] In an embodiment, block 115 may include providing a suction to the interior region of the processing chamber. The suction may be provided to the interior region via one or more outlets that are configured to receive one or more gaseous products from the processing chamber. The suction may facilitate quick and prompt removal of the gaseous products from the processing chamber. For example, the suction may help remove at least some of the gaseous products from the processing chamber before one or more secondarychemical reactions may occur, wherein such secondary chemical reactions may cause the formation of one or more less desirable chemicals.

[0047] In an embodiment, block 1 15 may include separating one or more of the products from each other. In such an embodiment, block 115 may include flowing the recovered products to one or more filters or separators that are configured to separate one or more of the products from each other. The separator may include a residence chamber for allowing the carbon solids to fall from the gasified or pyrolyzed feedstock, a cyclone separator, an electrostatic precipitation apparatus, a wet caustic scrubber, fixed media beds, fine fabric filters, or by the use of filter. Such filters may include a “candle” filter with ceramic material, a metallic filter with pores, or a fabric filter (e.g., a bag house). In an example, the separator may include removing the hydrohalic acids from the products recovered during block 115. The remove hydrohalic acids may exhibit a high purity (e.g., the hydrohalic acid forms at least 95 wt%, at least 99 wt%, or at least 99.9 wt% of the remove hydrohalic acids, excluding water). The removed hydrohalic acids may be sent to one or more locations (e.g., locations on or off site) to be used in one or more industrial applications. In a particular example, the hydrohalic acids separated from the other products is substantially anhydrous. In an example, the separator may remove syngas from the products. The hydrogen from the removed syngas may be used to provide power to the high temperature reactor that performs the method 100. In an example, the separator may remove one or more hydrogen-containing compounds from the recovered products. The method 100 may include using one or more of the products (e.g., hydrohalic acid, carbon products, hydrogen gas), such as recycling hydrogen back into the processing chamber. For example, the removed hydrogen-containing compounds may be provided back to the processing chamber or to a hydrogen source that is configured to provide one or more hydrogen-containing compounds to the processing chamber.

[0048] The method 100 may include storing one or more of the products (e.g., hydrohalic acid, carbon products, hydrogen gas). Such products may be used or sold.

[0049] In an embodiment, block 115 includes recovering carbon (e.g., pure carbon material), such as amorphous carbon, turbostratic carbon, or graphitic carbon formed at least in part from the feedstock. In an example, the carbon recovered during block 115 may include activated carbon. In an example, the carbon recovered during block 115 is not activated carbon. In such an example, the method 100 may include further processing the carbon to form activated carbon. Activated carbon with no, or essentially no impurities therein, may be pure carbon material. The pure carbon material recovered during block 115may be used to remove halocarbons from water or otherwise absorb halocarbons to form a sorbed carbon material (e.g., spent activated carbon). After the carbon is used to absorb the halocarbons, the sorbed carbon material (e.g., spent activated carbon) including the halocarbons thereon may be used as, or form part of the feedstock introduced during block 105. In other words, the method 100 may be a synergistic system that forms pure carbon material that is used to absorb halocarbons and the sorbed carbon material (e.g., spent activated carbon) with the absorbed halocarbons is reintroduced to the processing chamber to form more carbon materials, and so forth, such that the method 100 is consuming and producing carbon. Such carbon production may be carried out in addition or alternatively to production of hydrohalic acid(s).

[0050] The method 100 may be performed using any suitable high temperature reactor(s) or system including at least one high temperature reactor. FIGS. 2-5 are schematic illustrations of different high temperature reactors and systems that may be used to perform the method 100 or any of the methods disclosed herein.

[0051] FIG. 2 is a cross-sectional schematic of a system 200 (e.g., high temperature reactor) that may be used to at least partially decompose one or more halocarbons, according to an embodiment. The system 200 includes a processing chamber 210, one or more heating elements (e.g., joule heating electrodes 260, one or more induction heating elements 280, etc.), a feedstock inlet 230, and a controller 240 operably coupled to the heating elements and the feedstock inlet 230. The system 200 may also include a feedstock source 220 coupled to the feedstock inlet 230 that is configured to provide feedstock 232 to the processing chamber 210 and a hydrogen source 222 coupled to a hydrogen inlet 231 that is configured to provide excess hydrogen to the processing chamber 210.

[0052] The processing chamber 210 may include a container with a wall thickness and material composition sufficient to remain functional at the temperatures therein and / or to contain a molten material therein. For example, the processing chamber 210 may include a waste processing chamber (e.g., melter). The processing chamber 210 may include an interior region 212 to contain a feedstock 232 therein. For example, the processing chamber 210 may include a refractory metal lining disposed within a housing (e.g.. ceramic body) that is configured to be relatively non-reactive with the halocarbons, byproducts of the decomposed halocarbons (e.g., the hydrohalic acids), hydrogen, or any other material expected to be present in the interior region 212. In an example, the processing chamber 210 may include an inner refractory lining (e.g, ceramic body) disposed within an outer metalhousing. In some examples, the processing chamber may have a relatively shallow design to aid volumetric heating.

[0053] The feedstock source 220 is configured to provide the feedstock 232 to the processing chamber 210. Feedstock sources 220 may include municipal waste facilities, industrial waste facilities, nuclear waste facilities, liquid waste facilities, or the like. In an embodiment, the feedstock source 220 is a tank that is configured to hold the feedstock 232 therein until the processing chamber 210 can receive the feedstock 232. In an embodiment, the feedstock source 220 is an inlet of the system 200 that may receive the feedstock 232 from another source, such as a conveyor belt. The feedstock 232 held by the feedstock source 220 and / or provided to the processing chamber 210 may include any of the feedstocks disclosed herein.

[0054] In an example, the feedstock 232 may include a solid material, such as granulated solid material. In an example, the feedstock 232 may include solid material mixed with one or more liquid components to form a slurry. Examples of the liquid components may include water or one or more solvents. Providing the feedstock 232 as a slurry may decrease the likelihood that the solid particles become airborne. Such airborne particles may increase the likelihood that a portion of the feedstock 232 (e.g, halocarbons) enter the environment before being received into the processing chamber 210 or that the feedstock 232 flows out of the gaseous product outlet 272 before the halocarbons are sufficiently decomposed. It is noted that the liquid components may be selected to include hydrogen which may facilitate decomposition of the halocarbons into hydrohalic acids.

[0055] The feedstock 232 may be processed in the processing chamber 210 to include a molten material 236 and a cold cap 234 disposed on the molten material 236. The cold cap 234 may have an interface with the molten material 236 where the cold cap 234 is melted into the molten material 236. The primary mode of thermal energy transfer into the cold cap 234 is conduction from the molten material 236 (e.g., molten glass bath) below the cold cap 234. This conduction is the rate limiting step of the incorporation (e.g., melting) of the unmelted material (cold cap 234) into the molten material 236, the decomposition of the halocarbons, and the formation of gaseous products (e.g.. hydrogen, carbon monoxide, carbon dioxide, hydrohalic acids, etc.). There may also be accumulation of a gas layer or bubbles at the interface of the cold cap 234 and the molten material 236 further limiting thermal energy transfer into the cold cap 234. If bubbles are present, localized heating of the cold cap 234 directly above the bubble layer would also increase thermal energy transfer into the cold cap 234. It is noted that the bubble layer may be at least partially formed fromwater present in the feedstock 232. As such, at least partially removing the water from the feedstock 232 or using a non-water hydrogen source may decrease the number of bubbles in the bubble layer.

[0056] Additional heating may be added at the interface of the cold cap 234 and the molten material 236 in order to remove this processing rate limitation. However, it may be desirable to only enhance melting and dissolution as this may be the rate limiting step in melting, such as in a joule-heated or induction-heated melter process. Applying excess heat to the cold cap 234 could result in higher volatilization of feedstock 232 (e.g., waste feed components) into gas phase within the processing chamber 210 which may be unintentionally removed or vented with other gas phase constituents within the processing chamber 210 to prevent overpressure. Increasing the bulk temperature of the molten material 236 may increase the wear of melter components such as the refractory lining and electrodes (e.g., joule heating electrodes 260) that supply the electric current into the molten material 236. It may be desirable to prevent overheating of the cold cap 234 and thereby prevent and / or reduce emission of waste material from the surface of the cold cap 234 that faces the plenum (e.g., unfilled space of the interior region 212) of the processing chamber 210. Examples of elements that may be used to heat the cold cap 234 include using electromagnetic (e.g, microwave) radiation, joule hearing, or plasma from the plasma electrodes 262. Examples of electromagnetic radiation and methods of using the electromagnetic radiation to heat the cold cap 234 are disclosed in are disclosed in U.S. Patent No. 1 1 ,232,879 issued on January 25, 2022 and International Application No. PCT / US2025 / 018580 filed on March 5, 2025, the disclosure of each of which is incorporated herein, in its entirety, by this reference. Examples of plasma electrodes and methods of using the plasma electrodes are disclosed in more detail below and in U.S. Patent No. 9,771,532 issued on September 26, 2017, the disclosure of which is incorporated herein, in its entirety, by this reference.

[0057] In an embodiment, during use, the processing chamber 210 may include sufficient quantities of hydrogen that no outside source of hydrogen is needed to decompose the halocarbon. The processing chamber 210 may include sufficient quantities of hydrogen for a variety of reasons. In an example, the halocarbon itself and / or the feedstock include sufficient hydrogen to ensure that the halocarbon is converted into hydrohalic acid. In an example, the feedstock 232 may additionally include one or more of water, an organic solvent, or other material that includes hydrogen. Disposing the feedstock 232 in the processing chamber 210 may cause the partial decomposition of these materials therebyfreeing the hydrogen of these materials to react with the halogens of the halocarbon. In the embodiment where the processing chamber 210 may include sufficient quantities of hydrogen such that no outside source of hydrogen is needed to decompose the halocarbon, the system 200 may not include the hydrogen source 222 or the hydrogen source 222 may not be used to provide excess hydrogen to the processing chamber 210.

[0058] In an embodiment, during use, the processing chamber does not include sufficient quantities of hydrogen or it is otherwise desirable to provide more hydrogen to the processing chamber 210. In such an embodiment, the system 200 may include a hydrogen source 222 and the hydrogen source 222 is used to provide excess hydrogen into the processing chamber 210. The excess hydrogen provided by the hydrogen source 222 may include hydrogen gas (H2), water (H2O), methane (CH4), another alkane, another compound including hydrogen, or combinations of one or more of the foregoing. In an embodiment, the hydrogen source 222 is a tank that is configured to hold hydrogen therein (e.g., a compressed hydrogen or methane tank) until the processing chamber 210 can receive the (excess) hydrogen. In an embodiment, the hydrogen source 222 is an inlet of the system 200 that may receive the hydrogen source 222 from another source, such as from a water line. In such an embodiment, the hydrogen source 222 may include a heat source that is configured to vaporize the water into steam before providing the water to the processing chamber 210.

[0059] In examples, the system 200 may include one or more joule heating electrodes 260 positioned to heat the molten material 236. For example, one or more joule electrodes 260 may be positioned in the lower region of the processing chamber 210 to heat the molten material 236 to a selected temperature (e.g., maintain the molten material in a molten state). The processing chamber 210 may be a joule heated melter. The one or more joule heating electrodes 260 may melt the feedstock and vitrify the waste in the feedstock or maintain the feedstock in a molten state where the heating is provided by the passage of current between the joule heating electrodes 260.

[0060] In examples, the system 200 may include one or more induction heating elements 280. such as an induction coil or electromagnet disposed about one or more portions of the processing chamber 210 (e.g., the lower region). The induction coil or electromagnet may be operably coupled to an electronic oscillator.

[0061] In an example, the system 200 may include one or more plasma electrodes 262, such as a first plasma electrode and a second plasma electrode. The plasma electrodes 262 of the system 200 are configured to introduce energy into the processing chamber 210. Forexample, the system 200 is configured to provide electrical energy to the plasma electrodes 262 (e.g. , responsive to direction from the controller 240). The electrical energy provided to the plasma electrodes 262 may provide plasma heating to the processing chamber 210. The electrical energy provided to the plasma electrodes 262 may be used provide plasma heating directly to the feedstock 232. The plasma heating may at least partially decompose the feedstock 232 (e.g., halocarbon(s) therein) and provide energy for formation of the hydrohalic acid(s). The plasma heating may also facilitate calcining of the feedstock 232 and facilitate heating of the feedstock 232 and the molten material 239 which, in turn, facilitates incorporation of the cold cap 234 into the molten material 239 and decomposition of the halocarbons. The plasma heating may also vaporize, gasify, or otherwise decompose at least a portion of the feedstock 232 that flows therethrough, including gasifying and decomposing the halocarbons. The plasma heating may also induce reactions between any organic material in the feedstock 232 and oxygen in the processing chamber 210 to form syngas. It is currently believed that use of the plasma electrodes 262 in a processing chamber 210 facilitates maintaining a sufficiently high and uniform temperature in the processing chamber 210 to decompose the feedstock and form hydrohalic acid(s). Such temperature control can be achieved using less joule heating than is possible without the plasma electrodes 262. Less joule heating in-glass, avoids the potential for over current and avoiding overheating of the glass which otherwise results in damaged refractory within the processing chamber 210. Further examples of the structures of the plasma enhanced melters and methods ofusing plasma enhanced melters are disclosed in U.S. Patent No. 9,771 ,532 issued on September 26, 2017, the disclosure of which was previously incorporated herein.

[0062] The system 200 may include one or more sensors 250 configured to detect one or more characteristics of the system 200. In an example, the system 200 may include one or more sensors 250 positioned to sense a temperature of one or more portions of the feedstock 232 (e.g., the cold cap 234) or the interior region 212 of the processing chamber 210. The one or more sensors 250 may include a millimeter wave pyrometer, infrared wave pyrometer, a scanning (e.g., infrared) thermometer, a laser thermometer, a thermocouple, or any other suitable temperature sensor. The one or more sensors 250 may include radiation detectors (e.g., Geiger counter) or spectrometers (e.g., atomic absorption spectrometer, inductively coupled plasma atomic emission spectrometer), a moisture sensor, or any other suitable sensor for detecting the presence or amount of a specific material or otherwise monitor the decomposition of the feedstock 232. The one or more sensors may be positioned to measure at least one of a volatile material, hydrogen gas, carbon dioxide, carbonmonoxide, hydrohalic acid, or halocarbon in gases emited from the processing chamber 210 (e.g., from the cold cap 234). The one or more sensors 250 may be positioned to measure the temperature of the surface of the cold cap 234, chemical emissions of one or more components from the cold cap 234, or the temperature of emissions from the cold cap 234.

[0063] The system 200 includes the controller 240. The controller 240 may be operably coupled to one or more components of the system 200 via one or more connections 244 (e.g, wireless or hardwire connections) to control the system 200. For example, the controller 240 may be operably coupled to the heating elements, the feedstock source 220 and / or the feedstock inlet 230, the hydrogen source 222 and / or the hydrogen inlet 231, the gaseous product outlet 272 or any other outlet of the system 200. The controller 240 may control the components of the system 200 responsive to one or more characteristics of the system 200 detected by the sensors 250.

[0064] In an embodiment, the controller 240 can control the feedstock source 220 or the feedstock inlet 230 to control the input of the feedstock 232 into the processing chamber 210. In an example, the controller 240 can control whether the feedstock source 220 or the feedstock inlet 230 provides the feedstock 232 in batches and when each batch of feedstock 232 is provided. In an example, the controller 240 can control whether the feedstock source 220 or the feedstock inlet 230 provides the feedstock 232 continuously and the rate at which the feedstock 232 is provided. In an embodiment, the controller 240 can control whether the hydrogen source 222 or the hydrogen inlet 231 provides the excess hydrogen to the processing chamber 210 and, if provided, the quantity of excess hydrogen that is provided.

[0065] In an embodiment, the controller 240 may control the operation of the system 200 depending on products that are being produced by the system 200, as detected by the sensors 250. For example, the sensors 250 may detect that not substantially all of the halocarbons are being decomposed in the processing chamber or not substantially all of the halogens of the halocarbons are forming hydrohalic acids. In such an example, the controller 240 may control the components of the system 200 to improve decomposition of the halocarbons or improve conversion of the halocarbons into hydrohalic acids. Such control may include decreasing the flow of the feedstock 232 into the processing chamber 210 to allow beter control of the decomposition and conversion of the halocarbons, increasing the quantity of hydrogen in the processing chamber 210, modifying the temperature of the processing chamber 210 (e.g., increasing the temperature of the processing chamber 210), decreasing a suction provided to the processing chamber 210 to increase dwell time in the processing chamber 210, etc.

[0066] FIG. 3 is a schematic of a system 300 (e.g., high temperature reactor), according to an embodiment. The system 300 may be configured to perform the example method 100 or any of the other methods disclosed herein. Except as otherwise disclosed herein, the system 300 may be the same as or substantially similar to any of the systems disclosed herein. Also, except as otherwise disclosed herein, the features of the system 300 disclosed below may be used in any of the systems disclosed herein.

[0067] The system 300 includes a processing chamber 310 having a reaction interior region 312 therein. The reaction interior region 312 includes a bed of particles 314 disposed therein. The bed of particles 314 can be a fluidized bed or packed bed during use. The processing chamber 310 includes a feedstock input 316 having a feedstock inlet 330 fluidly connected to the reaction interior region 312. The processing chamber 310 includes a distributor plate 318 in the reaction interior region 312, such as at the bottom of the reaction interior region 312. The feedstock inlet 330 may be fluidly connected to the distributor plate 318 to distribute the input feedstock across a lateral plane or crosssection of the reaction interior region 312. The processing chamber 310 may include induction coils 315 disposed around the bed of particles 314. The induction coils 315 may be used to heat the bed of particles. In an embodiment, during use, the bed of particles 314 is fluidized by fluid (e.g., at least the feedstock) flowing upwardly therethrough. In an embodiment, the bed of particles 314 is a packed bed that is not fluidized by fluid. In such an embodiment, the system 300 may include a grate on a side of the bed of particles 314 opposite the distributor plate 318 that maintains the bed of particles 314 in a packed state and minimizes fluidization of the bed of particles 314. The bed of particles 314 may be heated at least in part by one or more of the induction coils 315, one or more joule electrodes disposed in the reaction interior region, or one or more plasma heating electrodes disposed in the rection interior region 312 and / or bed of particles 314. The bed of particles may be heated to at least a temperature that causes decomposition and conversion of any halocarbons in the feedstock as disclosed herein. The temperature of the bed of particles 314 may include any of the temperatures disclosed herein. Product gases and carbon (e.g., solids) are removed from the processing chamber 310 via output conduit 319. Output conduit 319 may be coupled to a separator 324 for separating the hydrogen gas product from the solid carbon product.

[0068] The processing chamber 310 includes a vertical tube (e.g., cylinder) constructed from an electrically non-conductive insulating material such as high alumina refractory materials forming at least a portion of the walls 311 (e.g., inner walls) thereof. In someexamples, the walls 311 include a multilayer construction with at least an inner wall and an outer wall. The walls 311 may include non-conductive insulating bricks, mortar, etc. on the inner wall. Accordingly, the walls 311 of the processing chamber 310 may be refractory walls. Other materials that exhibit some thermal insulating characteristics and are electrically non-conductive may be utilized. The walls 311 (e.g., outer walls) may include one or more metals, such as refractory metals. For example, an outer wall may include a metal wall. In such examples, the inner wall may include insulating bricks and mortar as disclosed above. The walls 311 (e g., at least the outer wall) may form a substantially fluid tight seal to retain fluids within the processing chamber 310. In the case of induction heating, no solidly continuous conducting material (e.g., the inner walls) should be present between the induction coils 315 and the particles in the bed of particles 314.

[0069] The inner dimensions of the walls 311 form the reaction interior region 312 within the processing chamber 310. The reaction interior region 312 includes a portion holding the bed of particles 314. The reaction interior region 312 may include ahead space above the bed of particles 314. The headspace may be fluidly connected to output conduit 319.

[0070] A lateral dimension(s) of the reaction interior region 312 where the bed of particles (e.g., fluidized bed) is disposed may vary' as a function of height above a bottom of the reaction interior region 312. For example, the inner lateral dimensions of the reaction interior region 312 may vary as a function of height in the reaction interior region 312. In examples, the reaction interior region 312 may widen above the bed of particles 314 in the headspace to a widest dimension. For example and as shown in FIG. 3, the reaction interior region 312 may include a particle disengagement section wherein the dimensions of the reaction chamber are increased to allow the carbon particles to disengage from the gaseous products produced via pyrolysis. In some examples, the lateral dimensions of the reaction interior region 312 may remain constant or may narrow or widen as a function of height within the reaction interior region 312.

[0071] Although the system 300 shown in FIG. 3 has a constant lateral dimension(s) (e.g., radius) at the bed of particles 314, it can be advantageous to vary the lateral dimension(s) as a function of height. This variation can increase conversion efficiency and reduce the heating power used to gasify, pyrolyze, or otherwise decompose the feedstock. For example, it can be advantageous for the radius to increase as function of height above the bottom of the bed of particles 314. With variable diameter, the local velocity of thefeedstock can be adjusted, in order to provide appropriate conditions for fluidization of the bed of particles 314 and residence time of the feedstock passing therethrough.

[0072] The bed of particles 314 includes a plurality of particles in the reaction interior region 312. The particles in the bed of particles 314 may include one or more of electrically conductive carbon or graphite particles. In some examples, other electrically conductive particles may be used. The bed of particles 314 may consist of, or consist essentially of, electrically conductive carbon particles (e.g., may be only carbon or graphite). For example, metal catalysts or metals may not be present in the bed of particles 314. The particles may be selected to be heated by electromagnetic heating (e.g., induction) and to heat the feedstock passing therethrough and to catalyze pyrolysis reaction therewith. In an example, metal catalysts or metals may be present in the bed of particles 314, such as to provide catalytic effect in addition to electrical conductivity. One or more of the size, weight, or porosity of the particles in the bed of particles may be selected to provide a selected heat absorption from the electromagnetic heating (e.g., inductive, microwave, etc.), pyrolysis reaction speed, particle drop rate within the fluidized bed. or the like. The preferred particulate material in the fluidized bed may be doped silicon dioxide, doped silicon carbide, carbon, or graphite or other electrically conductive (or magnetic) materials. In an embodiment, the bed of particles 314 includes silicon carbide doped or impregnated particles with an absorbed noble metal. It is currently believed that the silicon carbide or doped or impregnated particles with an absorbed noble metal are effective at breaking the halogen-carbon bonds at the surfaces thereof.

[0073] The bed of particles 314 includes a fluidized bed. The bed of particles 314 may be fluidized at least by the feedstock flowing upward therethrough. In some examples, an inert gas (e.g.. nitrogen) may alternatively or additionally be flowed upward through the bed of particles 314 to fluidize the particles. In some examples, the gases may include one or more of hydrogen, methane, or oxygen (e.g., air), such as to combust within the bed of particles 314. In some examples, the gases may change during operation, such as starting the fluidization with hydrogen and oxygen or an inert gas and switching over to hydrocarbon gas feedstock when the fluidized bed is at a selected temperature. The composition of the gas flowing through the bed of particles 314 may change as a function of height within the bed of particles, such as having a higher hydrogen content in upper portions of the bed of particles 314. For example, as the halocarbon is cracked, the composition of the fluidizing gas will change to hydrogen, hydrohalic acids, syngas, carbon dioxide, carbon monoxide or mixtures of any of the foregoing. As previously discussed, alternatively, the bed of particles314 may be a packed bed due to the presence of a grate on a side of the bed of particles 314 opposite the distributor plate 318.

[0074] The system 300 includes an induction unit for heating the bed of particles 314. The induction coils 315 heat the bed of particles 314 to at least the reaction temperature (e.g., pyrolysis or cracking temperature) of the feedstock (e.g., methane or other components of feedstock). The induction coils 315 of the induction unit induce an alternating electromagnetic field in conductive material (e.g.. a susceptor such as silicon dioxide, carbon, or graphite particles in the bed of particles 314) to heat the material (and halocarbon(s)) via eddy currents or any other electrical means. Inductive heating provides a way to directly heat particles in the bed of particles 314 (when fluidized or when not fluidized), not through convection, radiation, or conduction from other heated elements. In examples, the thermal energy input to the bed of particles 314 includes inductively coupling alternating current with electrically conductive or magnetic particles (e.g., carbon or graphite particles) thereby heating the particles via non-contact and non-line-of-sight methods. Magnetic particles may be heated up to the Curie temperature.

[0075] The induction coils 315 may be part of an induction unit surrounding the bed of particles 314. The induction coils 315 may be operably coupled to an energy source or power supply for supplying alternating electric current thereto. Although the induction coil 315 in FIG. 3 shows uniformly vertically spaced turns, the turns may be closer or farther spaced in one or more vertical locations to adjust the heating profile of the induction heating. The heating profile can be controlled by using open loop control that uses predetermined information about the effect of the heating profile on various system performance parameters. The induction coils 315 may include any number of coils. The induction coils 315 may include one or more sets of induction coils. The induction coils 315 may include coils of any material capable of inductively heating a material adjacent to the coil, such as within the diameter of the coils, via alternating current passed through the coil. Such material may include copper. The induction coils 315 may be disposed within the wall 311 as shown, such as between the outer and inner surfaces of the wall 311. In some examples, the induction coils may be disposed inside of the wall 311. such as in the reaction interior region 312. In some examples, the induction coils may be disposed outside of the wall 311. In such examples, no conductive materials may be disposed between the induction coils 315 and the bed of particles 314. In some examples, the induction coils 315 may be vertically disposed along at least a portion of the longitudinal axis of bed of particles 314.

[0076] During use, feedstock is introduced into an inlet in the refractory wall of the bed conversion unit and is preheated by the heat that is provided by the induction coils 315. The feedstock can be preheated in a heat exchanger. The heat of the processed gases can be used to partially increasing the temperature of the feedstock minimizing the required external power. The inductive heating couples very7effectively to the carbon particles in the bed of particles 314. producing temperatures in the range of 900° C. to 3,500° C. The high temperature provides very effective conversion of the feedstock. Cracking feedstock is highly endothermic, but one or more of the external heating sources disclosed herein maintain the appropriate temperature for the process.

[0077] In some examples, the induction coils 315 may be hollow to accommodate input of feedstock therethrough. In such examples, the feedstock may be at least partially preheated prior to input into the reaction interior region 312. In some examples, the conduit for inputting the feedstock may be run in parallel to the induction coils 315, such as within the wall 311 to allow the feedstock to at least partially preheat prior to input into the reaction interior region 312. In such examples, the conduit may be wound around at least a portion of the reaction interior region 312.1n some examples, the feedstock may be introduced into the bed of particles via a conduit that is separate and distinct from the induction coils, such as directly from the feedstock source.

[0078] The processing chamber 310 may be configured as an updraft reactor, wherein the processing chamber 310 includes a feedstock inlet 330 at a bottom of the reaction interior region 312. The feedstock inlet 330 may be fluidly connected to the distributor plate 318 to supply feedstock via the feedstock input 316. The distributor plate 318 may be a manifold for splitting a single stream into a plurality of streams. For example, the distributor plate 318 may diffuse the single stream of feedstock into a plurality of streams across a lateral cross-section or plane of the reaction interior region 312. While distributor plates 318 are disclosed herein, reactors may utilize alternative configurations for flowing gas into the reaction chamber to form the fluidized bed, including a spouted bed operation with one or more inlet orifices for the incoming gas, or the like. For example, the distributor plate 318 may be eliminated and the fluidized bed may be operated as a spouted bed or other types of orifices could be used to introduce the feedstock into the bottom of reaction interior region 312.

[0079] The processing chamber 310 is operably coupled to at least one feedstock source 320 directly, via the feedstock input 316, or both. The processing chamber 310 may also be operably coupled to a hydrogen source 322.

[0080] As the feedstock is flowed through the bed of particles, the temperature in the bed of particles 314 at or above the decomposition temperature of the halocarbon, the feedstock at least partially converts into one or more desired products, such as one or more hydrohalic acids. The products may be collected removed therefrom, such as via the output conduit 319.

[0081] The products may be moved to the separator 324 for separating the products from each other, such as hydrogen, hydrohalic acids, and solid carbon from each other. The separator 324 may include a residence chamber for allowing the carbon solids to fall from the decomposed feedstock, a cyclone separator, an electrostatic precipitation apparatus, or by the use of a filter. Such filters may include a “candle” filter with ceramic material, a metallic filter with pores, or a fabric filter (e.g., a bag house). The separator 324 may include an outlet for removing the hydrogen, an outlet for removing the hydrohalic acids, an outlet from removing the carbon therefrom, and one or more outlets from removing any other products. The outlet for removing carbon may be in the bottom of the separator 324. The separator 324 may include one or more filters for preventing carbon from passing through the outlet for removing hydrogen and / or hydrohalic acids.

[0082] One or more of plasma heating, joule heating, or micro wave (or millimeter) heating can be used in addition to or alternatively to the inductive heating disclosed above. These heating sources can be used to provide advantageous variations in the heating as a function of position in the reaction chamber — specifically in the bed of particles — or in the case of microwave heating, heating of the carbon that is released above the bed.

[0083] Further examples of structures and features that may be included in the system 300 or any of the other systems disclosed herein are disclosed in U.S. Patent Application No. 17 / 907,340 filed on March 26, 2021. the disclosure of which is incorporated herein, in its entirety, by this reference.

[0084] FIG. 4 is a schematic of a system 400, according to an embodiment. The system 400 may be configured to perform the example method 100 or any of the other methods disclosed herein. Except as otherwise disclosed herein, the system 400 may be the same as or substantially similar to any of the systems disclosed herein. Also, except as otherwise disclosed herein, the features of the system 400 disclosed below may be used in any of the systems disclosed herein.

[0085] The system 400 includes a gasifier 402 and a high temperature reactor 404. The gasifier 402 may be positioned upstream from the high temperature reactor 404. The gasifier 402 is configured to receive a feedstock 432 from a feedstock source 420. The gasifier 402is configured to at least partially gasify organic materials of the feedstock 432 received thereby. For example, the gasifier 402 may convert the organic materials of the feedstock 432 into carbon monoxide, carbon dioxide, hydrogen, or other products. The gasifier 402 may at least partially decompose the halocarbons in the feedstock 432.

[0086] The gasifier 402 may be configured to control the atmosphere thereof. In an embodiment, the gasifier 402 may be configured to at least partially gasify’ the feedstock 432 in a substantially non-oxidizing atmosphere. In such an embodiment, the chamber 456 may be under partial vacuum, an inert gas may be flowed into the chamber 456, or the chamber 456 otherwise exhibits a substantially non-oxidizing atmosphere (e.g., reducing conditions). In an embodiment, the chamber 456 may include an oxidizing atmosphere, for example, by providing oxygen, carbon dioxide, water, or other oxy gen-containing materials. The atmosphere in the gasifier 402 may be used to control the ratio of hydrogen, carbon monoxide, and carbon dioxide that is formed while at least partially gasify ing the feedstock 432. The atmosphere in the gasifier 402 may also facilitate or otherwise affect the decomposition of the halocarbon and may facilitate conversion of the halocarbon in the gasifier 402 and / or subsequent high temperature reactor 404.

[0087] The gasifier 402 may be in fluid communication with the high temperature reactor 404 such that the at least partially gasified and / or converted feedstock 432 produced by the gasifier 402 is provided to the high temperature reactor 404. For example, as shown, the gasifier 402 and the high temperature reactor 404 may be separated from each other by grate 406 which may facilitate dispersion of the feedstock 432 and control the amount of solid feedstock 432 that flows into the high temperature reactor. The grate 406 may be an active grate or inactive grate. The gasifier 402 may be connected to the high temperature reactor 404 using other structures, such as one or more conduits or conveyors.

[0088] The gasifier 452 includes one or more walls 454 defining a chamber 456. The gasifier 402 may include one or more heating elements that are configured to heat the chamber 456. The heating elements of the gasifier 402 may include any of the heating elements disclosed herein, such as joule heating, inductive heating, plasma heating, or other heating elements. In an example, the one or more heating elements are configured to cause the gasifier 402 to exhibit any of the decomposition temperatures disclosed herein. In an example, the one or more heating elements are configured to cause the gasifier 402 to exhibit a temperature of about 500 °C to about 1000 °C, such as about 500 °C to about 700°C, about 600 °C to about 800 °C, about 700 °C to about 900 °C, or about 800 °C to about 1000 °C. In an example, the gasifier 402 exhibits a temperature that is less than the high temperaturereactor 404. such as when the gasifier 402 is configured to at least partially gasify the feedstock 432 whereas the high temperature reactor 404 is configured to convert the halocarbons into hydrohalic acids or other compounds. Further examples of gasifiers are disclosed in U.S. Patent No. 8,685,121 filed on November 10, 2010, the disclosure of which is incorporated herein, in its entirety', by this reference.

[0089] The high temperature reactor 404 may facilitate conversion of the at least partially gasified feedstock 432 (e.g.. at least partially decomposed halocarbon(s)) into one or more desired products, such as convert the halocarbons in the feedstock 432 into hydrohalic acid. In an example, the high temperature reactor 404 is the same as or substantially similar to processing chamber 210 or the processing chamber 310 (e.g., the high temperature reactor 404 includes a hydrogen source 422). In an example, the high temperature reactor 404 may include any high temperature reactor known in the art.

[0090] Flowing the feedstock 432 through the gasifier 402 before the feedstock 432 reaches the high temperature reactor 404 may facilitate operation of the high temperature reactor 404. For example, the gasifier 402 may heat and dry the feedstock 432 before the feedstock 432 reaches the high temperature reactor 404, both of which may facilitate heating the feedstock 432 in the high temperature reactor 404 and minimize temperature drops in the high temperature reactor 404. The gasifier 402 may also provide better control of the reactions occurring in the high temperature reactor 404 (and products formed therefrom) by controlling the ratio of chemicals reaching the high temperature reactor 404.

[0091] FIG. 5 is a schematic of a system 500 that is configured to decompose one or more halocarbons, according to an embodiment. Except as otherwise disclosed herein, the system 500 is the same as or substantially similar to any of the systems disclosed herein. Further, the features of the system 500 may be used in any of the systems disclosed herein.

[0092] The system 500 includes one or more sources of material that are to be decomposed. For example, as shown, the system 500 includes a feedstock source 520 that is configured to hold and / or supply feedstock that includes or is suspected to include the halocarbons and a hydrogen source 522 that is configured to hold and / or supply excess hydrogen. The system 500 may include at least one additional source 526 that is distinct from the feedstock source 520 and the hydrogen source 522. In an example, the additional source 526 may be configured to provide municipal waste, industrial waste (e.g., waste generated during electronic chip manufacturing processes, waste electrical and electronic equipment), biomass, coal, or other material that does not include and is not suspected toinclude halocarbons. In an example, the additional source 526 is configured to provide oxygen, steam, glass (e.g., for the molten material), or any other suitable material.

[0093] In the illustrated embodiment, the sources of material(s) of the system 500 are configured to supply their materials to a gasifier 502. The gasifier 502 may be the same as or substantially similar to the gasifier 402 of FIG. 4 or another gasifier known in the art. In an embodiment, one or more of the sources of material of the system 500 are not configured to supply their materials to the gasifier 502. In such an embodiment, one or more source of materials (e.g. , the hydrogen source 522 and / or the additional source 526) may be configured to provide their materials to the high temperature reactor 504 or any other portion of the system 500 (e.g, the fluidized or packed bed reactor). In an embodiment, the gasifier 502 may be omitted from the system 500. In such an embodiment, the sources of material of the system 500 may provide their materials directly to the high temperature reactor 504 or any other portion of the system 500.

[0094] The system 500 may include a high temperature reactor 504. The high temperature reactor 504 may be the same as or substantially similar to any of the high temperature reactors disclosed herein. In a particular embodiment, the high temperature reactor 504 may include a plasma enhanced melter that is the same as or substantially similar to the system 200 shown in FIG. 2. In an embodiment, as shown, the high temperature reactor 504 may receive at least an at least partially gasified feedstock from the gasifier 502. In an embodiment, the high temperature reactor 504 may receive materials from another source, such as directly from one or more of the sources of material or a fluidized or packed bed reactor. In an embodiment, the system 500 includes a grate between the gasifier 502 and the high temperature reactor 504.

[0095] The high temperature reactor 504 may output one or more products. For example, the high temperature reactor 504 may output vitrified glass 551 and carbon (not shown), such as amorphous carbon, turbostratic carbon, or graphitic carbon depending on the temperature of the high temperature reactor 504. In an example, the high temperature reactor 504 may output one or more gaseous products, such as hydrohalic acids.

[0096] The high temperature reactor 504 may output the gaseous product or other products to a thermal residence chamber 552. The thermal residence chamber 552 provide additional residence time at high temperature (e.g., any of the decomposition temperatures disclosed herein) to help gasification and / or hydrohalic acid conversion reactions reach completion. For instance, some of the halocarbons may not be completely decomposed in the high temperature reactor (e.g., due to a short residence time in the high temperaturereactor 504 or by bypassing the plasma formed by the plasma electrodes) or not all of the halogens reacted with hydrogen to form hydrohalic acids. The thermal residence chamber 552 provides a location and conditions for continued decomposition of the halocarbons and / or formation of the hydrohalic acids. In an example, a mix of fuel gas and oxygen or just oxygen is provided from an oxygen / fuel source 553 to offset heat losses from the thermal residence chamber to ensure that the incoming products stay at the target temperature to allow reactions to reach equilibrium before exiting the thermal residence chamber 552. The thermal residence chamber 552 may also be coupled to the hydrogen source 552 or another hydrogen source to ensure that there is sufficient hydrogen in the thermal residence chamber 552 to substantially completely convert the halogens from the halocarbon(s) into hydrohalic acid. It is noted that, in some embodiments, the thermal residence chamber 552 may be omitted from the system 500.

[0097] In an embodiment, the system 500 includes a quencher 554 downstream from the high temperature reactor 504 (e.g., downstream of the thermal residence chamber 552). The quencher 554 is configured to decrease the temperature of the products outputted by the high temperature reactor 504 which may facilitate filtering, separation, and / or other dow nstream processing of the products. In an embodiment, the quencher 554 may cool the products using an inert gas, recycled syngas, atomized water spray, or any other relatively cold fluid.

[0098] The system 500 may include one or more filters or separators 555. In an example, the filters or separators 555 may include a wet caustic scrubber that uses a caustic solution (e.g., recirculated caustic solution) in a spray tower to cool the products and remove water. The wet caustic scrubber may also include a packed column to remove acid gases (e.g, hydrohalic acids) from the products. The wet caustic filter may also provide additional caustic solutions to the products to control the pH of the products. In an example, the filters or separators 555 may include an induced draft blower that pulls the products through the upstream equipment to provide a slight vacuum and control overall system pressure while also providing positive pressure to move the products through the downstream equipment. In an example, the filters or separators 555 may include guard beds including fixed media beds that remove additional trace materials from the products, including organics, hydrogen sulfide (H2S), and filter bed particulate. In an example, the filters or separators 555 may include a baghouse particulate filtration device that includes fine fabric filters to remove entrained solids from the products. The baghouse particulate filtration device may be configured to provide a reverse pulse jet of compressed gas to shake accumulated solids offthe filter bags, where the solids fall into a receiving containing below the baghouse. In an example, the filters or separators 555 may include a combination of any of the filters or separators disclosed herein.

[0099] The filters and separators 555 may output one or more products, such as hydrohalic acids 556, one or more solid products 557 (e.g., amorphous carbon, turbostratic carbon, or graphitic carbon), or one or more gaseous or liquid products 558 (e.g., syngas, hydrogen, methane or other alkane, oxygen, or water). It is noted that the one or more gaseous or liquid products 558 may be recycled back to one or more components of the system 500, such as the hydrogen-containing compounds to the hydrogen source 522, oxygen or syngas to the oxygen / fuel source 553, or water or syngas to the quencher 554.

[0100] The system 500 may include one or more components other than or in addition to the components illustrated in FIG. 5. In an embodiment, the system 500 may include a fluidized or packed bed reactor (e.g., the fluidized or packed bed reactor illustrated in FIG. 3) that is distinct from the high temperature reactor 504 (e.g., the high temperature reactor 504 is a plasma enhanced melter). In an example, the fluidized or packed bed reactor may replace the gasifier 502 or the thermal residence chamber 552. In such an example, the fluidized or packed bed reactor may perform the function of the component that it replaces. In an example, the fluidized or packed bed reactor may be positioned before the gasifier 502 (at point A) to help heat the feedstock or other material before the feedstock or material reaches the gasifier 502. In an example, the fluidized or packed bed reactor may be between the gasifier 502 and the high temperature reactor 504 (at point B) to further react the feedstock before the feedstock reaches the high temperature reactor 504. In an example, the fluidized or packed bed reactor may be between the high temperature reactor 504 and the thermal residence chamber 552 (at point C) to more completely decompose and convert the feedstock into desired material before the products react the thermal residence chamber 552 (e.g., the fluidized or packed bed reactor provides a higher temperature for reactions than the thermal residence chamber 552). In an example, the fluidized or packed bed reactor may be positioned between the thermal residence chamber 552 and the quencher 554 (at point D) to provide a final opportunity to help the gasification reactions reach completion. In an embodiment, one or more components of the system 500 may be omitted.

[0101] The following examples provide further detail in connection with the specific embodiments described above. In particular, the following examples disclose methods and systems for decomposing and converting halocarbon. It is noted that the prophetic examples provided below were determined using a mass balance analysis assuming that substantiallyall of the halocarbons are destroyed. The following working examples may form part of any of the methods disclosed herein and may be performed using any of the systems disclosed herein.

[0102] Working Example 1: Steam reforming to destroy spent activated carbon with PFAS absorbed:

[0103] A sample of granular activated carbon (“GAC”) was loaded with approximately 25 mg / kg of PF AS. The sample was then fed to the InEnTec plasma enhanced melter (“PEM”) reactor (having both plasma arc heating and joule heating to form a molten glass bath in the vessel) at a feed rate of 20 to 25 Ib / hr (11.34 kg / hr). The process was conducted over a 4 day period consisting of 6-7 hours of processing each day. The system took approximately 1-2 hours to reach steady state upon initiation of feeding. The PEM reactor was kept between 1000°C and 1400°C during the run. Once at steady state the material was fed for approximately 5 hours or until material is completely consumed, at which point the operation was deemed completed. The process was smooth without any interruptions over the first 3 days of operation. Sufficient water was fed to carry out steam reforming on the solids. Table 1 below shows results for PFAS removal on a spent GAC substrate in a PEM gasifierTABLE 1

[0104] The entire amount of GAC was destroyed in the reactor and PFAS destruction efficiencies of greater than 99.999999% were achieved.

[0105] Prophetic Example 2: Steam reforming with PFAS:

[0106] A waste stream contaminated with approximately 25 mg / kg of PFAS is fed in the same configuration as Example 1 with the same operating conditions. The expected results for PFAS removal in a PEM gasifier are shown below in table 2:TABLE 2

[0107] Destruction of the waste is complete.

[0108] Prophetic Example 3: Steam reforming with HFC- 134a:

[0109] HFC-134a (CH2FCF3, Tetrafluoroethane) is fed with water to the PEM gasifier in the same manner as Example 1 with the same conditions. The expected results for HFC- 134a removal in a PEM gasifier are as follows:TABLE 3

[0110] Destruction of the HFC-134a is complete.

[0111] Prophetic Example 4: Thermal cracking with spent activated carbon with PF AS absorbed:

[0112] A sample of GAC is exposed to a mixture of PF AS to a composition of 25 mg / kg of GAC. The sample is then charged to a reactor fitted with induction coils and a graphite counter electrode. Power is turned on and the reactor is heated to between 1000 and 1400 °C.

[0113] Natural gas is fed to the reactor continuously for several hours. During the time of the reaction, the off gases are measured and have (expected) ranges of the following:TABLE 4

[0114] Upon completion the carbon is removed from the reactor. During processing, 12 g of additional carbon is formed in the reactor for every' 16 g of natural gas fed. This carbon, along with the initial carbon is re-exposed to PFAS as in step 1 of this example. The uptake of PF AS is expected to be identical showing that the carbon has been regenerated.

[0115] The generated carbon is evaluated using Raman and is expected to be consistent with an amorphous carbon.

[0116] A portion of the generated carbon is separated from the initial carbon by elutriation and isolated. This carbon is expected to show < 100 ppb F content by inductively coupled plasma spectroscopy (“ICP”), indicating that the generated carbon is free of absorbed PFAS.

[0117] Prophetic Example 5: Repeat of Example 4 at higher temperatures

[0118] In this example, the reactor of example 4 is prepared and fed in the same manner as example 4 except at two higher temperatures, specifically, in condition a) 1700 °K, and in condition b) 2000 °K. Gas composition results for Example 5a and 5b are the same as in Example 4, and the carbon generation rate is the same. The carbon for all temperatures is expected to show < 100 ppb F content by ICP. indicating that the generated carbon is free of absorbed PFAS.

[0119] The resulting carbon is analyzed by Raman spectroscopy and consistent with the carbon is amorphous at 1500 °K (Example 4), turbostratic at 1700 °K, and graphitic at 2000 °K. Details are as follows:

[0120] The material made at 2000 °K can be analyzed using Raman spectroscopy and is expected to be found to be substantially free of defects as measured by the ratio of G to D bands in the Raman Spectrum. The sample is expected to have a G / D ratio > 3. (D bands being associated with mesophase materials and G bands being associated with graphitic planes). This indicates a material substantially graphitic.

[0121] The material made at 1700 °K is expected to have a G / D peak ratio between 1 (which would be amorphous or similar to carbon black) and 3.5 (which approaches that of graphite) in the Raman spectrum consistent with turbostratic carbon.

[0122] The material made at 1400 °K is expected to have a G / D peak ratio around 1 indicating an amorphous carbon, similar to carbon black.

[0123] Prophetic Example 6: Thermal cracking with HFC-134a: a) at lower temperatures to make carbon black, b) at medium temperatures to make hard or turbostratic carbon, and c) at higher temperatures to make graphitic carbon.

[0124] Several grams of conductive carbon is charged to a reactor fitted with induction coils and a graphite counter electrode. Power is turned on and the reactor is heated in three separate experiments to a) 1500 °K (lower temp.), b) 1700 °K (medium temp.), and c) 2000 °K (higher temp.).

[0125] A 60:40 molar ratio feed of HFC-134a:methane is fed to the reactor for several hours. During the time of the reaction, the off gases are measured and expected to have average values shown in Table 5.TABLE 5

[0126] Upon completion the carbon is removed from the reactor. During processing, 24 g of additional carbon is formed in the reactor per 102 g of HFC-134a fed. This carbon for all temperatures is expected to have < 100 ppb F content by ICP, indicating that the generated carbon is free of absorbed fluorocarbons.

[0127] The resulting carbon is analyzed by Raman spectroscopy, and is expected to be amorphous at 1500 °K, turbostratic at 1700 °K, and graphitic at 2000 °K.

[0128] Prophetic Example 7: Thermal cracking with HFC-152a (Difluoroethane, CH3CHF2) without methane co-feed: a) at lower temperatures to make carbon black, b) atmedium temperatures to make hard or turbostratic carbon, and c) at higher temperatures to make graphitic carbon.

[0129] Several grams of conductive carbon is charged to a reactor fitted with induction coils and a graphite counter electrode. Power is turned on and the reactor is heated in three separate experiments to a) 1500 °K, b) 1700 °K, and c) 2000 °K.

[0130] HFC-152a is fed to the reactor for several hours. During the time of the reaction, the off gases were measured and are expected to have average values shown in Table 6.TABLE 6

[0131] Upon completion the carbon is removed from the reactor. During processing, 24 g of additional carbon is formed in the reactor per 66 g of HFC-152a. This carbon for all temperatures is expected to show < 100 ppb F content by ICP, indicating that the generated carbon is free of absorbed fluorocarbons.

[0132] The resulting carbon is analyzed by Raman spectroscopy, and is expected to be amorphous at 1500 °K, turbostratic at 1700 °K, and graphitic at 2000 °K.

[0133] Prophetic Example 8: Thermal cracking with HFC-L52a and HFC-134a in a near equimolar amount to make minimal hydrogen: a) at lower temperatures to make carbon black, b) at medium temperatures to make hard or turbostratic carbon, and c) at higher temperatures to make graphitic carbon.

[0134] Several grams of conductive carbon is charged to a reactor fitted with induction coils and a graphite counter electrode. Power is turned on and the reactor is heated in three separate experiments to a) 1500 °K, b) 1700 °K, and c) 2000 °K.

[0135] A 51 :49 molar blend of HFC-152a:HFC-134a is fed to the reactor for several hours. During the time of the reaction the off gases, are measured and expected to have average values are shown in Table 7.TABLE 7

[0136] Upon completion the carbon is removed from the reactor. During processing, 24 g of additional carbon is formed in the reactor per every 80 - 85 g of mixed HFC-152a / 134a fed to the reactor. This carbon for all temperatures is expected to show < 100 ppb F content by ICP, indicating that the generated carbon is free of absorbed fluorocarbons.

[0137] The resulting carbon is analyzed by Raman spectroscopy, and is expected to be amorphous at 1500 °K, turbostratic at 1700 °K, and graphitic at 2000 °K.

[0138] Prophetic Example 9: Thermal cracking with HFC-152a and PFAS without methane a) at lower temperatures to make carbon black, b) at medium temperatures to make hard or turbostratic carbon, and c) at higher temperatures to make graphitic carbon.

[0139] Several grams of conductive carbon is charged to a reactor fitted with induction coils and a graphite counter electrode. Power is turned on and the reactor is heated in three separate experiments to a) 1500 °K, b) 1700 °K, and c) 2000 °K.

[0140] HFC-152a is fed to the reactor with a 1000 ppm PFAS for several hours. During the time of the reaction the off gases, are measured and expected to have average values shown in Table 8.TABLE 8

[0141] (PFAS is not expected to exceed 100 ppb at any point during testing).

[0142] Upon completion, the carbon is removed from the reactor. During processing, 24 g of additional carbon is formed in the reactor per 66 g of HFC-152a fed. This carbon for all temperatures is expected to show < 100 ppb F content by ICP, indicating that the generated carbon is free of absorbed Fluorocarbons.

[0143] The resulting carbon is analyzed by Raman spectroscopy, and is expected to be amorphous at 1500 °K, turbostratic at 1700 °K, and graphitic at 2000 °K.

[0144] The processes and systems disclosed herein destroy 99.99999% PFAS and halochemicals with no residual halocarbon moieties; produce excess hydrogen for commerce; selectively convert halogens to halogenic acids that can be sold for commerce;and can be run such that acids are created in anhydrous forms which are easily purified for commerce.

[0145] As used herein, the term '‘about” or “substantially” refers to an allowable variance of the term modified by “about” by ±10% or ±5%. Further, the terms “less than,” “or less,” “greater than”, “more than,"’ or “or more” include as an endpoint, the value that is modified by the terms “less than,” “or less,” “greater than,” “more than,'’ or “or more.”

[0146] While various aspects and embodiments have been disclosed herein, other aspects and embodiments are contemplated. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting. Additionally, the words “including,” “having,’’ and variants thereof (e.g, “includes” and “has”) as used herein, including the claims, shall be open ended and have the same meaning as the word “comprising” and variants thereof (e.g., “comprise” and “comprises”).

Claims

CLAIMSWhat is claimed is:

1. A method to at least partially decompose one or more halocarbons, the method comprising: introducing feedstock into a high temperature reactor, the feedstock including or suspected to include the one or more halocarbons; converting at least a portion of the one or more halocarbons into at least one hydrohalic acid; and recovering one or more products from the high temperature reactor, the one or more products including the at least one hydrohalic acid.

2. The method of claim 1. wherein introducing the feedstock into a high temperature reactor includes introducing the feedstock into the high temperature reactor exhibiting a temperature of 1000 °C to 3000 °C.

3. The method of claim 1, wherein introducing feedstock into a high temperature reactor includes introducing the feedstock into the high temperature reactor in batches.

4. The method of claim 1, wherein introducing feedstock into a high temperature reactor includes continuously introducing feedstock into the high temperature reactor.

5. The method of claim 1, wherein the feedstock includes carbon including at least a portion of the one or more halocarbons trapped therein or thereon.

6. The method of claim 1, wherein the feedstock includes at least one of municipal solid waste, industrial waste, biomass, coal, or natural gas.

7. The method of claim 1. wherein converting at least a portion of the one or more halocarbons includes decomposing at least 99.99% of the one or more halocarbons.

8. The method of claim 1, wherein converting at least a portion of the one or more halocarbons includes decomposing at least 99.9999% of the one or more halocarbons.

9. The method of claim 1, wherein the one or more halocarbons are present in the one or more products at 100 parts per billion or less.

10. The method of claim 1, wherein the one or more products includes syngas.

11. The method of claim 1 , further comprising introducing excess hydrogen from a hydrogen source into the high temperature reactor.

12. The method of claim 11, wherein introducing excess hydrogen from a hydrogen source into the high temperature reactor includes introducing sufficient hydrogen that a molar ratio of hydrogen to halogen (moles hydrogen / moles halogen) is greater than 1.

13. The method of claim 11, wherein the hydrogen source includes water.

14. The method of claim 1, wherein no hydrogen source that is separate from the feedstock is introduced into the high temperature reactor.

15. A system to at least partially decompose one or more halocarbons, the system comprising: a processing chamber at least defining an interior region, a feedstock input, and a product output; a feedstock source configured to provide feedstock to the interior region via the feedstock input, the feedstock including or suspected to include the one or more halocarbons; and one or more heating elements configured to heat at least the interior region; wherein the system is configured to convert at least a portion of the one or more halocarbons into at least one hydrohalic acid and recover one or more products via the product output.

16. The system of claim 15, further comprising at least one plasma electrode at least partially disposed in the interior region of the processing chamber.

17. The system of claim 15, further comprising a synthesis gas generation unit or pyrolytic conversion unit located upstream from the processing chamber.

18. The system of claim 15, wherein the processing chamber forms part of a fluidized bed reactor or a packed bed reactor.

19. The system of claim 18, wherein the processing chamber includes a solid media disposed in the interior region, the solid media including at least one of silicon carbide or an absorbed noble metal that is doped or impregnated.

20. A method to at least partially decompose one or more halocarbons, the method comprising: introducing feedstock into a high temperature reactor, the feedstock including or suspected to include the one or more halocarbons; introducing excess hydrogen from a hydrogen source into the high temperature reactor such that a molar ratio of hydrogen to halogen (moles hydrogen / moles halogen) is greater than 1 ;converting substantially all of the one or more halocarbons into at least one hydrohalic acid; and recovering one or more products from the high temperature reactor, the one or more products including the at least one hydrohalic acid; wherein at least 99.99% of the one or more halocarbons are decomposed.

21. A method to at least partially decompose one or more halocarbons, the method comprising: introducing feedstock into a high temperature reactor, the feedstock including a sorbed carbon material having or suspected to have the one or more halocarbons absorbed thereon; converting at least a portion of the one or more halocarbons into at least one hydrohalic acid; producing pure carbon material that does not include the one or more halocarbons absorbed thereon; and recovering one or more products from the high temperature reactor, the one or more products including the at least one hydrohalic acid and the pure carbon material.

22. The method of claim 21, further comprising, after recovering one or more products from the high temperature reactor, using the pure carbon material recovered from the high temperature reactor to absorb the one or more halocarbons.

23. The method of claim 22. further comprising, after using the pure carbon material recovered from the high temperature reactor to absorb the one or more halocarbons, introducing the sorbed carbon material and the one or more halocarbons absorbed thereon into the high temperature reactor.

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