Electromagnetic wave and thermal containment structure for containment of electromagnetic waves and high temperature solid and gaseous species within a chemical reactor

Abstract

Provided are reaction vessels comprising: a) a reaction chamber; b) a thermal containment structure, the thermal containment structure comprising at least one thermally insulating body having a high specific heat capacity and shaped to reduce thermal conductivity between structures in the reactor vessel; and c) an electromagnetic wave containment structure, the electromagnetic wave containment structure comprising at least one electromagnetic-reflective body having a high melting point and a high recrystallization point, wherein the at least one electromagnetic-reflective body is shaped with a smooth innermost surface for maintaining electromagnetic waves in the reaction chamber.

Description

ELECTROMAGNETIC WAVE AND THERMAL CONTAINMENT STRUCTURE FOR CONTAINMENT OF ELECTROMAGNETIC WAVES AND HIGH TEMPERATURE SOLID AND GASEOUS SPECIES WITHIN A CHEMICAL REACTORTECHNICAL FIELD

[0001] This invention relates to the field of chemical reactors and more particularly to the vessels used to carry out chemical reactions that result in the production of hydrogen, for example hydrogen production by methane pyrolysis.BACKGROUND

[0002] In Sylvain Rodat, Stephane Abanades, Julien Coulie, Gilles Flamant, "Kinetic modelling of methane decomposition in a tubular solar reactor", Chemical Engineering Journal, 2009, 146 (1 ), pp.120-127, 10.1016 / j.cej.2008.09.008. hal-02567110v2, it is stated "Solar methane cracking is a promising pathway to produce hydrogen and carbon black with the bonus of zero CO2 emission. A kinetic simulation of the methane decomposition in a tubular solar chemical reactor prototype is presented. This reactor is composed of four independent tubular reaction zones inserted in a graphite cavity receiver. Chemical reaction modelling is carried out thanks to the Dsmoke software, using a detailed kinetic scheme for the wide range modelling of alkane transformation. First, a kinetic analysis of the chemical system is presented to determine the sequence of methane cracking and a sensitivity analysis of the results on temperature (in the range 1500-2300 K) and on natural gas composition is performed. Then, a kinetic simulation of the solar reactor is proposed and implemented, in which each tubular reaction zone is modelled by three plug-flow reactors in series representing the preheating, isothermal, and cooling zones of the reactor. It predicts the evolution of gas species concentrations as a function of residence time. Comparisons with experimental results between 1670 and 1770 K show good agreement for CH4 conversion, and CH4 and H2 off-gas compositions."

[0003] In US 4,435,374, Helm, Jr. states "A process for the gasification of carbon of solid carbonaceous material to form carbon monoxide and hydrogen by contacting thematerial with superheated steam and irradiating the product of said contacting with an amount of microwave energy sufficient to gasify said carbon, and apparatus therefor."

[0004] In US 5,532,462, Butwell, Robert J. states "A reaction vessel used in industrial applications is heated by a multiple mode microwave beam that is directed to an interior wall of the reaction vessel. The beam is in an inclined-angular fashion and the wall is arranged so the beam is absorbed and reflected from it many times to provide a helicallike reflection and absorption pattern within the vessel interior to uniformly heat the vessel wall and the material. A microwave isolator connected between a source of the microwave energy and the reaction vessel includes a quartz plate and a seal for compensating disparities in thermal expansion coefficients between the plate and a housing for the plate."

[0005] In US 7,744,810, Nagata, Kazuhiro, et al. state "A reactor has a casing composed of a magnesia-based refractory, and a bottom plate composed of an MgO- graphite mixed refractory is disposed on a bottom part of this casing. A graphite crucible is provided at a bottom of the reactor, and the graphite crucible and the reactor are joined together by a magnesia cylinder. Iron ore powder, coal powder, and other such raw materials supplied into the reactor are irradiated with microwaves from microwave oscillators and are heated. The iron ore is reduced, and the resulting molten pig iron flows out through a hole into a crucible, and then is poured out of the crucible through another hole into a ladle. It is thereby possible to manufacture molten pig iron with high energy efficiency, instead of using blast-furnace iron-making."

[0006] In US 2011 / 0224473, Denton, Mark S. states "Systems and processes for reducing the volume of radioactive waste materials through pyrolysis and vitrification carried out by microwave heating and, in some instances, a combination of microwave heating and inductive heating. In some embodiments, the microwave-enhanced vitrification system comprises a microwave system for treating waste material combined with a modular vitrification system that uses inductive heating to vitrify waste material. The final product of the microwave-enhanced vitrification system is a denser, compacted radioactive waste product."

[0007] In US 2011 / 0262336, Rauleder, Hartwig, et al. state "The invention relates to a complete method for producing pure silicon that is suitable for use as solar-gradesilicon, comprising the reduction of a silicon oxide, purified by acidic precipitation from an aqueous solution of a silicon oxide dissolved in an aqueous phase, using one or more pure carbon sources, the purified silicon oxide being obtained, in particular, by the precipitation of a silicon oxide dissolved in an aqueous phase in an acidif ier. The invention also relates to a formulation containing an activator and to a device for producing silicon, a reactor and electrodes."

[0008] In US 2018 / 0237709, Potgieter, Deon John states "A device and method for cleaning producer gas includes a filter bed housing and a microwave chamber. The filter bed housing comprises an inlet for carbon-based material and a spent carbon outlet. The microwave chamber comprises a permeable top and wave guides around the perimeter through which microwaves can be introduced into the device using magnetrons. The method comprises using the device by filling the filter bed housing with carbon-based material, introducing microwaves into the microwave chamber using the magnetrons and wave guides, passing the gas through carbon-based material in the filter bed chamber, the microwave chamber, the gas permeable top and the gas outlet."

[0009] In US 2022 / 098045, Stapela, Annelie, et al. state "A pyrolysis method and a pyrolysis reactor for recovering silica from a polymer waste material containing silica, particularly a rubber or plastics waste material containing silica, using thermal decomposition for separating silica from at least one non-silica component of the polymer waste material, are disclosed. The waste material is delivered to a pyrolytic chamber and heated to a decomposition temperature of at least one non-silica component of the waste material by microwave radiation. The decomposition temperature is selected such that the at least one non-silica component includes a higher microwave absorptivity than silica."

[0010] In US 2023 / 0159326, Surma, Jeffrey E., et al. state "Embodiments of the invention relate to systems and methods for cracking hydrocarbons into hydrogen gas and carbon using heating of a fluidized bed. The systems and methods utilize electrically conductive carbon or graphite particles as a fluidized bed material for heating hydrocarbon feedstock to at least a pyrolysis temperature. The electrically conductive carbon, graphite, or other particles may be heated by electrically powered sources that include induction heating, microwave heating, millimeter wave heating,joule heating and / or plasma heating. Combustion heating may also be employed in varying amounts with varying combinations of electrically powered heating sources."SUMMARY

[0011] This invention is based, at least in part, on the elucidation of how to make a reactor vessel suitable for heating a reaction using microwaves and / or radio waves while simultaneously making the reactor vessel impermeable to hydrogen.

[0012] In illustrative embodiments of the present invention, there is provided a thermal containment structure comprising: a) at least one thermally insulating body having a high specific heat capacity and shaped to reduce thermal conductivity between structures in a reactor vessel.

[0013] In illustrative embodiments of the present invention, there is provided a thermal containment structure described herein wherein the at least one body comprises at least one solid refractory material selected from the group consisting of: refractory fibre blankets; polycrystaline wool blankets; ceramic fiber blankets; refractory ceramic fibres; insulating castables; lightweight insulating castables; high-alumina, low-silica castables for severe abrasion; crystalline silica free castables; low iron, lightweight insulating castables; high strength insulating castables; pumpable and / or shotcretable insulating castables; high strength insulating castables; low iron, lightweight high strength castables; lightweight, high strength fireclay castables; lower cement, high strength, medium density castables; pumpable insulating castables; high purity bubble alumina castables; extremely lightweight castable block insulations; and mixtures thereof.

[0014] In illustrative embodiments of the present invention, there is provided a thermal containment structure described herein wherein the at least one body comprises at least one solid refractory material selected from the group consisting of: MAFTEC™ Blanket, Denka Alcen™ Blanket, Cerablanket™, Cerachem™ Blanket, and Kaowool™ Papers, Blazelite™, Blazelite 80™, Kast-o-lite 97 L plus™, Delta T Crete™, GreenCast94™, MAFTEC™ Blanket, Denka Alcen™ Blanket, Cerablanket™, Cerachem™ Blanket, Kaowool™ Papers, and any combination thereof.

[0015] In illustrative embodiments of the present invention, there is provided a thermal containment structure described herein wherein the at least one body comprises at least one solid refractory material selected from the group consisting of materials set out in Table 1 below.

[0016] In illustrative embodiments of the present invention, there is provided a thermal containment structure described herein wherein the at least one body comprises at least one gas selected from the group consisting of: an inert gas, argon, nitrogen, and a mixture of gases that does not contain oxygen.

[0017] In illustrative embodiments of the present invention, there is provided a thermal containment structure described herein wherein the at least one body comprises at least one gas selected from the group consisting of: an inert gas, nitrogen, and a mixture of gases that does not contain oxygen.

[0018] In illustrative embodiments, there is provided a thermal containment structure comprising at least one thermally insulating body having a high specific heat capacity and shaped to reduce thermal conductivity between structures in a reactor vessel. The at least one body comprises one or more of: refractory fibre blankets; polycrystaline wool blankets; ceramic fiber blankets; refractory ceramic fibres; insulating castables; lightweight insulating castables; high-alumina, low-silica castables for severe abrasion; crystalline silica free castables; low iron, lightweight insulating castables; high strength insulating castables; pumpable and / or shotcretable insulating castables; high strength insulating castables; low iron, lightweight high strength castables; lightweight, high strength fireclay castables; lower cement, high strength, medium density castables; pumpable insulating castables; high purity bubble alumina castables; extremely lightweight castable block insulations; an inert gas; argon; nitrogen; a mixture of gases that does not contain oxygen; and mixtures thereof. The at least one body may comprise a plurality of bodies, comprising at least a solid refractory material and an inert gas.

[0019] In illustrative embodiments, there is provided a thermal containment structure comprising at least one thermally insulating body having a high specific heat capacity and shaped to reduce thermal conductivity between structures in a reactor vessel. The at least one body comprises one or more of: refractory fibre blankets; polycrystalinewool blankets; ceramic fiber blankets; refractory ceramic fibres; insulating castables; lightweight insulating castables; high-alumina, low-silica castables for severe abrasion; crystalline silica free castables; low iron, lightweight insulating castables; high strength insulating castables; pumpable and / or shotcretable insulating castables; high strength insulating castables; low iron, lightweight high strength castables; lightweight, high strength fireclay castables; lower cement, high strength, medium density castables; pumpable insulating castables; high purity bubble alumina castables; extremely lightweight castable block insulations; an inert gas; nitrogen; a mixture of gases that does not contain oxygen; and mixtures thereof. The at least one body may comprise a plurality of bodies, comprising at least a solid refractory material and an inert gas.

[0020] In illustrative embodiments of the present invention, there is provided a thermal containment structure described herein wherein the at least one body comprises a plurality of bodies, wherein a first plurality of bodies comprise a solid refractory material and a second plurality of bodies comprise an inert gas.

[0021] In illustrative embodiments of the present invention, there is provided a thermal containment structure described herein wherein the at least one body is shaped to reduce gas leakage from the reaction chamber.

[0022] In illustrative embodiments of the present invention, there is provided a thermal containment structure described herein wherein the thermal containment structure is attached at the top of the thermal containment structure to a first structural structure.

[0023] In illustrative embodiments of the present invention, there is provided a thermal containment structure described herein wherein the thermal containment structure is physically connected at the bottom of the thermal containment structure to a second structural structure.

[0024] In illustrative embodiments of the present invention, there is provided a method of reducing gas leakage from the reaction chamber, the method comprising equalizing pressure between a thermal containment structure described herein and the reaction chamber, utilizing a purging gas.

[0025] In illustrative embodiments of the present invention, there is provided a method described herein wherein the purging gas is selected from the group consisting of: an inert gas, nitrogen, argon, and a reactant gas.

[0026] In illustrative embodiments of the present invention, there is provided a method described herein wherein the purging gas is selected from the group consisting of: an inert gas, nitrogen, and a reactant gas.

[0027] In illustrative embodiments of the present invention, there is provided an electromagnetic wave containment structure comprising: a) at least one electromagnetic-reflective body having a high melting point and a high recrystallization point, wherein the at least one body is shaped with a smooth innermost surface for maintaining electromagnetic waves in a reaction chamber.

[0028] In illustrative embodiments of the present invention, there is provided an electromagnetic wave containment structure described herein, wherein the at least one body comprises a single, closed shaped body having a top, a bottom, and a side.

[0029] In illustrative embodiments of the present invention, there is provided an electromagnetic wave containment structure described herein, wherein the at least one body comprises at least two bodies, a first body having an open shape thereby forming a side and a second body having a flat, planar shape thereby forming top.

[0030] In illustrative embodiments of the present invention, there is provided an electromagnetic wave containment structure described herein, wherein the at least one body comprises a plurality of bodies, wherein a first plurality of bodies comprises an open shape thereby forming a side and a second plurality of bodies comprises a flat, planar shape thereby forming a top.

[0031] In some embodiments of the present invention, there is provided an electromagnetic wave containment structure comprising: a) at least one electromagnetic-reflective body having a high melting point and a high recrystallization point, wherein the at least one body is shaped with a smooth innermost surface for maintaining electromagnetic waves in a reaction chamber. In some of these embodiments, the at least one body is generally cylindrical shaped, and / or is highly electrically conductive. In some of these embodiments, the at least one body is comprised of at least one selected from the group consisting of: nickel, chromium, aluminum, titanium, zirconium, molybdenum, tungsten, niobium, rhodium, osmium and any combination thereof. In some of these embodiments, the at least one body comprises at least one or more solid regions and at least one or more non-solid regions.

[0032] In illustrative embodiments of the present invention, there is provided an electromagnetic wave containment structure described herein, wherein the at least one body is generally cylindrical shaped.

[0033] In illustrative embodiments of the present invention, there is provided an electromagnetic wave containment structure described herein, wherein the at least one body is highly electrically conductive.

[0034] In illustrative embodiments of the present invention, there is provided an electromagnetic wave containment structure described herein, wherein the at least one body is comprised of at least one selected from the group consisting of: nickel, chromium, aluminum, titanium, zirconium, molybdenum, tungsten, niobium, rhodium, osmium and any combination thereof.

[0035] In illustrative embodiments of the present invention, there is provided an electromagnetic wave containment structure described herein, wherein the at least one body is comprised of at least one alloy selected from the group consisting of: molybdenum lanthanum oxide, titanium zirconium molybdenum, chromium aluminum molybdenum and nickel chromium.

[0036] In illustrative embodiments of the present invention, there is provided an electromagnetic wave containment structure described herein, wherein the at least one body consists of a molybdenum lanthanum oxide alloy.

[0037] In illustrative embodiments of the present invention, there is provided an electromagnetic wave containment structure described herein, wherein the at least one body consists of a titanium zirconium molybdenum alloy.

[0038] In illustrative embodiments of the present invention, there is provided an electromagnetic wave containment structure described herein, wherein the at least one body consists of a nickel chromium alloy.

[0039] In illustrative embodiments of the present invention, there is provided an electromagnetic wave containment structure described herein, wherein the at least one body comprises at least one or more solid regions and at least one or more non-solid regions.

[0040] In illustrative embodiments of the present invention, there is provided an electromagnetic wave containment structure described herein, wherein the at least onebody comprises at least two bodies and at least two layers, wherein the at least two layers are separated by at least one thermal expansion gap.

[0041] In illustrative embodiments of the present invention, there is provided a reactor vessel comprising: a) a reaction chamber; b) a thermal containment structure, the thermal containment structure comprising at least one thermally insulating body having a high specific heat capacity and shaped to reduce thermal conductivity between structures in the reactor vessel; and c) an electromagnetic wave containment structure, the electromagnetic wave containment structure comprising at least one electromagnetic-reflective body having a high melting point and a high recrystallization point, wherein the at least one electromagnetic-reflective body is shaped with a smooth innermost surface for maintaining electromagnetic waves in the reaction chamber.

[0042] In illustrative embodiments of the present invention, there is provided a reactor vessel comprising: a) a reaction chamber; b) a multi-region zone, the multi region zone comprising: i. a thermal containment structure, the thermal containment structure 66 comprising at least one thermally insulating body having a high specific heat capacity and shaped to reduce thermal conductivity between structures in the reactor vessel; and ii. an electromagnetic wave containment structure, the electromagnetic wave containment structure comprising at least one electromagnetic-reflective body having a high melting point and a high recrystallization point, wherein the at least one electromagnetic-reflective body is shaped with a smooth innermost surface for maintaining electromagnetic waves in the reaction chamber.

[0043] In illustrative embodiments of the present invention, there is provided a reactor vessel described herein, wherein the at least one electromagnetic-reflective body comprises a single, closed shaped electromagnetic-reflective body having a top, a bottom, and a side.

[0044] In illustrative embodiments of the present invention, there is provided a reactor vessel described herein, wherein the at least one electromagnetic-reflective body comprises at least two electromagnetic-reflective bodies, a first electromagnetic- reflective body having an open shape thereby forming a side and a second electromagnetic-reflective body having a flat, planar shape thereby forming a top.

[0045] In illustrative embodiments of the present invention, there is provided a reactor vessel described herein, wherein the at least one electromagnetic-reflective body comprises a plurality of electromagnetic-reflective bodies, wherein a first plurality of electromagnetic-reflective bodies comprises an open shape thereby forming a side and a second plurality of electromagnetic-reflective bodies comprise a flat, planar shape thereby forming a top.

[0046] In illustrative embodiments of the present invention, there is provided a reactor vessel described herein, wherein the at least one thermally insulating body comprises at least one solid refractory material selected from the group consisting of: MAFTEC™ Blanket, Denka Alcen™ Blanket, Cerablanket™, Cerachem™ Blanket, and Kaowool™ Papers, Blazelite™, Blazelite 80™, Kast-o-lite 97 L plus™, Delta T Crete™, GreenCast94™, MAFTEC™ Blanket, Denka Alcen™ Blanket, Cerablanket™, Cerachem™ Blanket, Kaowool™ Papers, and any combination thereof.

[0047] In illustrative embodiments of the present invention, there is provided a reactor vessel described herein, wherein the at least one thermally insulating body comprises at least one gas selected from the group consisting of: an inert gas, nitrogen, and a mixture of gases that does not contain oxygen.

[0048] In illustrative embodiments of the present invention, there is provided a reactor vessel described herein, wherein the at least one electromagnetic-reflective body is highly electrically conductive.

[0049] In illustrative embodiments of the present invention, there is provided a reactor vessel described herein, wherein the at least one electromagnetic-reflective body is comprised of at least one material selected from the group consisting of: copper, brass, steel, stainless steel, steel alloys, nickel, chromium, aluminum, titanium, zirconium, molybdenum, tungsten, niobium, rhodium, osmium, castable refractory, and any combination thereof.

[0050] In illustrative embodiments of the present invention, there is provided a reactor vessel described herein, wherein the at least one electromagnetic-reflective body is comprised of at least one alloy selected from the group consisting of: molybdenumlanthanum oxide, titanium zirconium molybdenum, chromium aluminum molybdenum nickel chromium, and castable refractory.

[0051] In illustrative embodiments of the present invention, there is provided a reactor vessel described herein, wherein the at least one electromagnetic-reflective body consists of a molybdenum lanthanum oxide alloy.

[0052] In illustrative embodiments of the present invention, there is provided a reactor vessel described herein, wherein the at least one electromagnetic-reflective body consists of a titanium zirconium molybdenum alloy.

[0053] In illustrative embodiments of the present invention, there is provided a reactor vessel described herein, wherein the at least one electromagnetic-reflective body consists of a nickel chromium alloy.

[0054] In illustrative embodiments of the present invention, there is provided a reactor vessel described herein, wherein the at least one thermally insulating body comprises a plurality of thermally insulating bodies, wherein a first plurality of thermally insulating bodies comprises a solid refractory material and a second plurality of thermally insulating bodies comprises an inert gas.

[0055] In illustrative embodiments of the present invention, there is provided a reactor vessel described herein, wherein the at least one thermally insulating body is shaped to reduce gas leakage from the reaction chamber.

[0056] In illustrative embodiments of the present invention, there is provided a reactor vessel described herein, wherein the thermal containment structure is attached at the top of the thermal containment structure to a first structural structure.

[0057] In illustrative embodiments of the present invention, there is provided a reactor vessel described herein, wherein the thermal containment structure is physically connected at the bottom of the thermal containment structure to a second structural structure.

[0058] In illustrative embodiments of the present invention, there is provided a reactor vessel described herein, wherein the at least one electromagnetic-reflective body is generally cylindrical shaped.

[0059] In illustrative embodiments of the present invention, there is provided a reactor vessel described herein, wherein the at least one electromagnetic-reflective body comprises at least one or more solid regions and at least one or more non-solid regions.

[0060] In illustrative embodiments of the present invention, there is provided a reactor vessel described herein, wherein the at least one electromagnetic-reflective body comprises at least two electromagnetic-reflective bodies and at least two layers, wherein the at least two layers are separated by at least one thermal expansion gap.

[0061] In illustrative embodiments of the present invention, there is provided a method of reducing gas leakage from the reaction chamber described herein, the method comprising equalizing pressure between the thermal containment structure described herein and the reaction chamber, utilizing a purging gas.

[0062] In illustrative embodiments of the present invention, there is provided a method described herein wherein the purging gas is selected from the group consisting of: an inert gas, nitrogen, argon, product gas, and a reactant gas.

[0063] In illustrative embodiments of the present invention, there is provided a method described herein wherein the purging gas is selected from the group consisting of: an inert gas, nitrogen, product gas, and a reactant gas.

[0064] Other aspects and features of the present invention will become apparent to those ordinarily skilled in the art upon review of the following description of specific embodiments of the invention in conjunction with the accompanying figures.BRIEF DESCRIPTION OF DRAWINGS

[0065] In drawings which illustrate embodiments of the invention,

[0066] Figure 1 is a flow diagram of a reactor vessel according to the present invention.

[0067] Figure 2 is an alternative embodiment of a flow diagram of a reactor vessel according to the present invention.

[0068] Figure 3 is an illustration of a cutaway of one embodiment of a reactor vessel.

[0069] Figure 4 is a close-up illustration of Section A from Figure 3, illustrating the detail of a portion from the top of the reactor vessel.

[0070] Figure 5 is a close-up of an embodiment of the reactor vessel from Figure 3.

[0071] Figure 6 is a close-up of section B from Figure 3, illustrating the detail of a portion from the bottom of the reactor vessel.DETAILED DESCRIPTION

[0072] Figure Legend

[0073] As used herein, the term “electromagnetic wave” refers to, unless otherwise stated, microwave and / or radio-wave. Examples of electromagnetic waves include, but are not limited to, microwaves and radio-waves. In some preferred embodiments electromagnetic wave means microwave. In some preferred embodiments electromagnetic wave means radio-wave.

[0074] As used herein, the term "microwave" refers to an electromagnetic wave having a wavelength in the range of 0.001 to 1 meters with corresponding frequencies of 300 GHz and 300 MHz. Common frequency bands for microwave heating include a frequency at or around 915 MHz, a frequency at or around 433 MHz, and a frequency at or around 2450 MHz, though other frequencies may be used in methods of the present invention, such as any frequency of 300 GHz or less.

[0075] As used herein, the term "radio-wave" refers to an electromagnetic wave having a frequency of less than 300 MHz. Often, radio-waves have a wavelength in the range of 300,000 to 1 meters with corresponding frequencies of 1 KHz and 300 MHz.Common frequency bands for radio-wave heating include a frequency at or around 20 KHz, though other frequencies may be used in methods of the present invention, such as about 1 KHz to about 200 MHz, about 1 KHz to about 100 MHz, about 1 KHz to about 50 MHz, about 1 KHz to about 1 MHz, about 1 KHz to about 1 00 KHz, about 1 KHz to about 50 KHz, about 1 KHz to about 20 KHz, and about 1 MHz to about 10 KHz.

[0076] Generally, the invention relates, at least in part, to a chemical reactor, shown generally at 10, whereby the source of heating is electromagnetic waves. The main components of the chemical reactor 10 are a reactor vessel 20 comprising a multiregion zone 60, a reaction chamber 30, an electromagnetic wave generator 40, anelectromagnetic wave applicator 45, at least one inlet 50, at least one outlet 70, a gas product capture container 80, a solid product capture container 90, together with the parts that connect these main components. The reactor vessel 20 may function as a microwave and / or radio-wave cavity.

[0077] The electromagnetic wave generator 40 may be any electromagnetic wave generator known to a person of skill in the art. For instance, the electromagnetic wave generator 40 may be a microwave and / or radio wave generator, such as any microwave and / or radio wave generator known to the person of skill in the art. In some embodiments, the electromagnetic wave generator 40 may be only a microwave generator and unable to generate radio waves. In some other embodiments, the electromagnetic wave generator 40 may be only a radio wave generator and unable to generate microwaves. In other embodiments still, the electromagnetic wave generator 40 may be able to generate both microwaves and radio waves and is a microwave and radio wave generator. The electromagnetic wave generator 40 is provided with electricity from an electricity source 100. Upon receiving power, the electromagnetic wave generator 40 produces electromagnetic waves.

[0078] The electromagnetic wave applicator 45, directs electromagnetic waves, such as microwaves and / or radio waves, from the electromagnetic wave generator 40 towards and ultimately into the reactor vessel 20. In some embodiments, there is at least one electromagnetic wave applicator 45. In other embodiments, there is a plurality of electromagnetic wave applicators 45. The electromagnetic wave applicator 45 terminates with a connection means 110. Electromagnetic waves from the electromagnetic wave applicator 45 pass through the connection means 110 into the reactor vessel 20. The connection means 110 provides a suitable seal so that electromagnetic waves pass into the reactor vessel 20 and do not leak from the electromagnetic wave applicator 45 or from the reactor vessel 20. In some embodiments the connection means 110 is any mechanical connection means that is known to the person of skill in the art. An example of a mechanical connection means could be a flange. The electromagnetic wave applicator 45 also enables a distance to be maintained between the electromagnetic wave generator 40 and the reactor vessel 20. This distance is of particular importance to protect the electromagnetic generator 40when the reactor vessel 20 is required to be very hot in order to carry out a particular chemical reaction.

[0079] The reactor vessel 20, is comprised of the multi-region zone 60 and the reaction chamber 30. The reaction chamber 30 is a space inside the reactor vessel 20 in which a chemical reaction may occur. The reaction chamber 30 is defined by an innermost region of the multi-region zone 60. Elements of the reactor vessel 20 may be electromagnetic wave-inert, microwave inert, radio wave inert, or both microwave inert and radio wave inert. In many embodiments, the multi region zone 60 comprises at least 3 functionally distinct structures: (i) an electromagnetic wave containment structure 64; (ii) a thermal containment structure 66; and (iii) a structural structure 68. Each of the functionally distinct structures (i) the electromagnetic wave containment structure 64, (ii) the thermal containment structure 66, and (iii) the structural structure 68 may comprise a single body, or more than one body. In the embodiments in which at least one of the electromagnetic wave containment structure 64, the thermal containment structure 66, and the structural structure 68 comprise more than one body, the more than one bodies may or may not be physically connected, but work together to provide the function that the functionally distinct structure is to provide. For example, the electromagnetic wave containment structure 64 may comprise a plurality of bodies, some of which are physically connected to each other and some of which are not connected to each other, but all of the plurality of bodies, connected or not, work together to contain electromagnetic waves in the reaction chamber 30. Similarly, a plurality of bodies may make up the thermal containment structure 66 and work together to contain heat. Further, a plurality of bodies may make up the structural structure 68 and work together to provide physical structure and stability.

[0080] The electromagnetic wave containment structure 64 is for containing electromagnetic waves, microwaves and / or radio-waves. The electromagnetic wave containment structure 64 is also often suitable for containing the chemical reaction such that reactants are adequately exposed to the correct conditions and products are adequately able to be removed from the reactor vessel 20. The electromagnetic wave containment structure 64 is also often suitable for protecting the other elements of themulti region zone 60 from reaction processes, which may or may not be as a result of exposure to electromagnetic waves and / or to exposure to process species.

[0081] The thermal containment structure 66 is for thermally insulating the reaction chamber 30. The thermal containment structure 66 is also often suitable for protecting the structural structure 68 from high temperatures. Further, the thermal containment structure 66 may often be suitable for reducing the thermal energy of any reactants and or products that escape the reaction chamber 30. The thermal containment structure 66 may also reduce gas leakage from reaction chamber 30.

[0082] The structural structure 68 is for providing structural stability to the chemical reactor 10 and for reducing gas leakage. Portions of the structural structure 68 may provide structural stability to a portion of the chemical reactor 10 and not to another portion. For example, one portion of the structural structure 68 may provide structural stability to one portion of the thermal containment structure 66 while a different portion of the structural structure 68 may provide structural stability to one portion of the electromagnetic wave containment structure 64 while a different portion of the structural structure may provide structure to yet another different portion of the structural structure 68.

[0083] The electromagnetic wave containment structure 64 may comprise at least one solid material. In some embodiments, the electromagnetic wave containment structure 64 may comprise at least two solid materials. In some embodiments, the electromagnetic wave containment structure 64 may comprise at least three solid materials. The solid material or materials of the electromagnetic wave containment structure 64 is typically made from electromagnetic-reflective materials, microwave reflective materials, radio wave reflective materials or both microwave reflective and radio wave reflective materials. In preferred embodiments, these microwave reflective materials and radio-wave reflective materials are materials that generally have high melting point values and can withstand high temperatures. Microwave reflective materials and radio wave reflective materials are materials that generally are highly electrically conductive. Examples include metals and metal alloys such as, but not limited to, stainless steel, carbon steel, brass, bronze, iron, copper, nickel, cobalt, silver, gold, aluminum, zinc, lead, chromium, manganese, titanium, molybdenum, tungsten,rhenium, osmium, niobium, tantalum, zirconium, and any other electrically conductive metal or metal alloy that is known to the person of skill in the art. Further examples include steel alloys, plated liners, copper liners, and silver liners. Preferred solid materials for the electromagnetic wave containment structure 64 may include materials that are comprised of nickel, chromium, aluminum, molybdenum, tungsten, niobium, rhenium, tantalum, titanium, zirconium, and other refractory materials. Preferred solid materials for the electromagnetic wave containment structure 64 have a high melting point, a high crystallization temperature, and are machinable and ductile materials. In certain embodiments, the electromagnetic wave containment structure 64 comprises solid regions, comprised of solid materials, and the electromagnetic wave containment structure 64 comprises non-solid regions, comprised of non-solid materials. In certain embodiments, the electromagnetic wave containment structure 64 comprises at least one or more solid regions and at least one or more non-solid regions. The non-solid regions may comprise particular gases and / or liquids. In some embodiments, the electromagnetic wave containment structure 64 is the same as the innermost region. In other embodiments, the electromagnetic wave containment structure 64 comprises a portion of the innermost region. In some embodiments, a portion of the electromagnetic wave containment structure 64 comprises the innermost region. In some embodiments, a portion of the electromagnetic wave containment structure 64 comprises a portion of the innermost region. In some embodiments, the electromagnetic wave containment structure 64 comprises the top portion of the innermost region. In other embodiments, the electromagnetic wave containment structure comprises all of the innermost region, except for the bottom.

[0084] There may be a top portion, a bottom portion, and / or a side portion of the electromagnetic wave containment structure 64. In embodiments having all of the top portion, the bottom portion, and the side portion, the electromagnetic wave containment structure 64 comprises an enclosed shape. In some embodiments, the enclosed shape is a cylinder. In some embodiments the electromagnetic wave containment structure 64 comprises the side portion and the top portion, but not the bottom portion. In some embodiments the electromagnetic wave containment structure 64 comprises the side portion and the bottom portion, but not the top portion. In some embodiments, the topportion is a flat, planar shape. In other embodiments, the top portion is concave, convex, dome-like, or any other shape known to a person of skill in the art. In some embodiments the side portion of the electromagnetic wave containment structure 64 is cylindrical or other shape. In some embodiments, the side portion is rectangular, oblong, or any other shape known to a person of skill in the art. These multiple portions of the electromagnetic wave containment structure 64 may be joined in any way known to one of skill in the art. It is preferable that the joining technique is compatible with the associated material and as long as the joining technique facilitates reduced electromagnetic wave leakage and gaseous species leakage from reaction chamber 30. Further, the resulting join of the joining technique should be a join that reduces or prevents microwave arcing. In some embodiments, the joining technique may involve an assembly of many components that comprise at least one electromagnetic wave sealing body. The electromagnetic wave sealing body may be a gasket, choke arrangement, packing, and / or other sealing body known to those of skill in the art. The at least one electromagnetic wave sealing body reduces and / or prevents electromagnetic waves from escaping reaction chamber 30, thereby increasing the efficiency of the chemical reaction within reaction chamber 30 as well as protecting other structures within multi region zone 60 from degradation and / or heating due to exposure to electromagnetic waves. The electromagnetic wave sealing bodies may be positioned at interfaces of or between bodies within the functional structures and / or at interfaces of or between bodies of different functional structures of the multi region zone 60. The sealing bodies may be positioned within grooves defined by bodies within the functional structures of the multi region zone 60. It is advantageous to ensure tight fitting between the top and side portions of the electromagnetic wave containment structure 64, the bottom and side portions of the electromagnetic wave containment structure 64 and / or the top, bottom and side portions of the electromagnetic wave containment structure 64 to reduce and / or minimize microwave, radio-wave and / or reaction species leakage and / or to reduce and / or minimize arcing that may occur between the portions during the operation of reactor vessel 20.

[0085] The relative position of the electromagnetic wave containment structure 64 is maintained in a relative position within the reactor vessel 20 by at least one attachmentmeans. The at least one attachment means may be any attachment means known to one of skill in the art. The at least one attachment may comprise one or more welds, rivets, interference fits, flanges and / or any combination of the attachment means. In some embodiments, interfaces between the at least one attachment means and the electromagnetic wave containment structure 64 and / or within the assembly of the at least one attachment means comprise at least one electromagnetic wave sealing body such as a gasket, choke arrangement, packing, and / or other sealing body known to those of skill in the art. The at least one sealing body may or may not be the same sealing body comprised within the joining assembly between top, bottom and / or side portions of the electromagnetic wave containment structure 64. Sealing bodies are advantageous because they reduce leakage of electromagnetic waves from the reaction chamber 30 and thereby reduce electromagnetic wave heating of components of the reactor vessel 20 and the multi region zone 60 that are not in direct contact with reaction chamber 30. In some embodiments, the at least one attachment means comprises one or more welds and / or rivets between portions of the electromagnetic wave containment structure 64 and the multi region zone 60. In some embodiments, the at least one attachment means comprise interference fits between portions of the electromagnetic wave containment structure 64 and the multi region zone 60. Interference fits may be facilitated by protrusions defined by the electromagnetic wave containment structure 64 wherein the protrusions may be maintained in relative position by tightfitting parts defined by any one of the structures comprised in the multi region zone 60 such as the electromagnetic wave containment structure 64, the thermal containment structure 66 and / or the structural structure 68. In some embodiments, the at least one attachment means comprise at least one flange on the electromagnetic wave containment structure 64 for engaging with at least one flange defined by a different body of a structure of the multi region zone 60. The flange on the electromagnetic wave containment structure 64 may engage with a body or a plurality of bodies of the thermal containment structure 66, the structural structure 68 and / or the electromagnetic wave containment structure 64 to form the at least one attachment means. In preferred embodiments, the electromagnetic wave containment structure 64 comprises a flange and a protrusion defined by the side portion of the electromagneticwave containment structure 64, wherein the flange engages with the structural structure 68 and the protrusion engages with the top and side portions of the electromagnetic wave containment structure 64. In preferred embodiments, the top portion of the electromagnetic wave containment structure 64 is welded to the top portion of the structural structure 68. In preferred embodiments, the bottom portion of the electromagnetic wave containment structure 64 engages with the structural structure 68 via an interference fit. It may be advantageous to use flanges and / or interference fits as it makes the innermost region more easily replaceable for inspection, maintenance, or once the lifespan of the innermost region is complete.

[0086] Flanges, and / or protrusions defined by the electromagnetic wave containment structure 64 may be formed by shaping a single body of the electromagnetic wave containment structure 64 with the flange, and / or protrusion. Alternatively, a flange, and / or protrusion may be formed by welding, fastening, brazing and / or riveting two bodies together such that the welded, fastened, brazed and / or riveted two bodies form a composite body that comprises a flange, and / or protrusion. Alternatively still, a plurality of flanges and / or protrusions may be achieved by both shaping individual single bodies and welding, fastening, brazing and / or riveting two bodies together to form additional flanges and / or protrusions.

[0087] The top, bottom and / or side portion of electromagnetic wave containment structure 64 may each independently comprise multiple layers, or may each independently comprise a single layer. In embodiments comprising multiple layers, the individual layers may be solid, liquid, or gaseous layers or combinations thereof. In preferred embodiments, the side portion of the electromagnetic wave containment structure 64 comprises at least two solid layers, an inner solid layer, and an outer solid layer. The inner solid layer is in direct contact with the reaction chamber 30. The outer solid layer is not in direct contact with the reaction chamber 30. In some embodiments, the solid layers comprised within the side portion of the electromagnetic wave containment structure 64 are separated by a space. The space may form a gaseous layer that may be filled with an inert gas and / or gaseous process species. It is preferable that the solid layers of each of the inner and outer layers comprised within the side portion of the electromagnetic wave containment structure 64 are not in directphysical contact with each other to accommodate thermal expansion. In some embodiments, the inner layer of the at least two solid layers comprised within the electromagnetic wave containment structure 64 defines the innermost side region of the multi region zone 60 wherein the innermost side region is in direct contact with process conditions that may be present in reaction chamber 30 and associated reaction species. It may be advantageous to have multiple side layers of the electromagnetic wave containment structure 64 to reduce electromagnetic wave and process species from leaking from the reaction chamber 30. This may enable a reduction to the temperature that the thermal containment structure 66 and the structural structure 68 are exposed to. This may also facilitate maintenance of the reactor vessel 20, which may lead to an increase in the overall lifetime of the electromagnetic wave containment structure 64. The increase in overall lifetime of the electromagnetic wave containment structure 64 may be achieved by replacing the innermost layer of the electromagnetic wave containment structure 64. Further, the space between the inner and outer solid layer of the electromagnetic wave containment structure 64 allows for radial thermal expansion of the inner solid layer that may occur due to high temperatures present in the reaction chamber 30 during the operation of the reactor vessel 20. In embodiments where electromagnetic wave containment structure 64 has multiple side layers, it may be advantageous to situate a portion of the thermal containment structure 66 between the multiple side layers of electromagnetic wave containment structure 64 to protect the outermost side layer of electromagnetic wave structure 64 and allow the innermost side layer of electromagnetic wave structure 64 to be exposed to higher process temperatures.

[0088] The multiple layers defined by the top, side and / or bottom portion of the electromagnetic wave containment structure 64 may be connected to one another or may be connected to the multi region zone 60, the thermal containment structure 66, the structural structure 68, or another body and / or layer within the electromagnetic wave containment structure 64. In some embodiments the outer and inner solid layers of the side portion of the electromagnetic wave containment structure 64 are directly connected to the structural structure 68. In some embodiments the outer solid layer of the electromagnetic wave containment structure 64 is attached to the structuralstructure 68 and the inner solid layer of the electromagnetic wave containment structure 64 is attached to the upper portion of the electromagnetic wave containment structure 64. In other embodiments the outer solid layer of the electromagnetic wave containment structure 64 is attached to the structural structure 68 and the inner solid layer of the electromagnetic wave containment structure 64 is attached to the side portion of the outer portion of the electromagnetic wave containment structure 64. In preferred embodiments, the outer solid layer of the electromagnetic wave containment structure 64 is attached to the structural structure 68 and the inner solid layer of the electromagnetic wave containment structure 64 maintains its position within the multi region zone 60 through engagement with the outer solid layer of the side portion of the electromagnetic wave containment structure 64 and the top portion of the electromagnetic wave containment structure 64. In preferred embodiments the interface between the inner solid layer and the outer solid layer and the top portion of the electromagnetic wave containment structure 64 comprise electromagnetic sealing bodies to reduce leakage of thermal energy and electromagnetic waves from the reaction chamber 30. Attachment of the inner solid layer to one or more structures comprised within multi region zone 60 may be facilitated by protrusions on the inner solid layer that engage in an interference fit to support the relative position of the inner solid layer. The protrusions may be any known to one of skill in the art such as flanges, horizontal lips, annular spacers, concentric rings, and / or other structures that come into physical contact.

[0089] In a preferred embodiment, the electromagnetic wave containment structure 64 is not directly physically secured at the bottom of reactor vessel 20 to accommodate for axial thermal expansion in a downward direction. In other embodiments, some portions of the electromagnetic wave containment structure 64 are secured directly to the bottom of the reactor vessel 20 and other portions of the electromagnetic wave containment structure 64 are not secured directly to the bottom of the reactor vessel 20. In some embodiments, the electromagnetic wave containment structure 64 is connected by engagement of a flange and / or protrusion with a groove in the structural structure 68 at the bottom of the reactor vessel 20. In some embodiments, the inner solid layer of the electromagnetic wave containment structure 64 is not physically connected at thebottom of the multi region zone 60. In some embodiments, a portion of the thermal containment structure 66 may be below the inner solid layer of the electromagnetic wave containment structure 64. The portion of the thermal containment structure 66 below the inner solid layer of the electromagnetic wave containment structure 64 may comprise a refractory blanket material. The portion of the thermal containment structure 66 below the inner solid layer of the electromagnetic wave containment structure 64 may reduce the escape of process materials from the reaction chamber 30. In preferred embodiments, the inner solid layer of the electromagnetic wave containment structure 64 is separated by a space between itself and the bottom of the multi region zone 60. In some embodiments, the space is occupied by refractory blanket material, such as Kaowool™, so as to reduce or eliminate carbon flowing from the reaction chamber 30 through the space and into other sections of the reaction vessel 20. The space at the bottom of the inner solid layer of the electromagnetic wave containment structure 64 is advantageous to allow for axial thermal expansion of the inner solid layer that may occur due to high temperatures present in the reaction chamber 30 during operation of the reactor vessel 20. Expansion of the inner solid layer of the electromagnetic wave containment structure 64 during high temperature operation of the reactor vessel 20, may result in a physical, nonpermanent connection between the inner solid layer and other bodies of the electromagnetic wave containment structure 64, the thermal containment structure 66 and / or the structural structure 68. Such a physical, nonpermanent connection is in the form of a friction fit and / or interference fit. In some embodiments where a refractory blanket is present in the space, the same friction fit and / or interference fit is still achieved, but the refractory blanket material is compressed and forms a part of such a fit. In preferred embodiments downward thermal expansion of the inner solid layer of the electromagnetic wave containment structure 64 results in a physical, nonpermanent connection between the bottom of the inner solid layer and a top portion of the bottom of the outer solid layer of the electromagnetic wave containment structure 64. The connection reduces the escape of process gases from inside the reaction chamber 30 during operation of the reactor vessel 20. In preferred embodiments, the outer solid layer of the electromagnetic wave containment structure 64 is connected to the structural structure 68 via an interference fit at the bottom of theouter solid layer. During the operation of the reactor vessel 20, the outer solid layer of the electromagnetic wave containment structure 64 may expand downward due to axial thermal expansion. In some embodiments, the portion of the structural structure 68 that is in physical contact with the bottom of the outer solid layer of the electromagnetic wave containment structure 64 comprises a compression apparatus that facilitates the axial thermal expansion of the outer solid layer. The compression apparatus may be any type of compression apparatus known to one of skill in the art such as an apparatus that comprises compressible material, such as compressible packing and / or springs. In preferred embodiments the compression apparatus defined by the structural structure 68 that is in contact with the outer solid layer of the electromagnetic wave containment structure 64 is a spring apparatus that can expand and contract to accommodate thermal expansion of the outer solid layer. In some embodiments, the interfaces between the bottom of the outer solid layer of the electromagnetic wave containment structure 64 and the structural structure 68 there is at least one additional, separate portion of the electromagnetic wave containment structure 64 which acts as an electromagnetic wave sealing body to reduce leaking of electromagnetic waves and process species during operation of the reactor vessel 20.

[0090] Individual layers of the at least one or more layers of the top, bottom and / or side portion of the electromagnetic wave containment structure 64 may comprise a plurality of electromagnetic wave reflective refractory bodies. The reflective refractory bodies comprise solid refractory material. In preferred embodiments, the solid refractory material has a melting point above 1 ,000 degrees Celsius and a recrystallization temperature above 1 ,000 degrees Celsius. In some embodiments, the solid refractory material comprises a material selected from the group consisting of nickel, chromium, aluminum, titanium, zirconium, molybdenum, tungsten, niobium, rhodium, osmium and any combination thereof. In some embodiments, the solid refractory material is an alloy. In some embodiments, the alloy is selected from the group consisting of: molybdenum lanthanum oxide, titanium zirconium molybdenum, chromium aluminum molybdenum, and nickel chromium. In some preferred embodiments, the alloy is molybdenum lanthanum oxide. In some preferred embodiments, the alloy is titanium zirconium molybdenum. In some preferred embodiments, the alloy is a nickel chromium alloy.

[0091] Placement and / or connection of the plurality of refractory bodies via a construction method results in the formation of at least one functional electromagnetic wave containment structure 64. The plurality of refractory bodies may comprise at least one body that defines a flange and / or a protrusion. In preferred embodiments, a portion of the at least one functional electromagnetic wave containment structure 64 comprises the innermost region of the multi region zone 60. It is advantageous for the portion of the at least one functional electromagnetic wave containment structure 64 that comprises the innermost region to define a smooth surface to facilitate efficient reflection of electromagnetic waves within the reaction chamber 30 to ensure effective heat transfer within the reaction chamber 30 during operation of the reactor vessel 20. Further, it is advantageous for the portion of the at least one functional electromagnetic wave containment structure 64 that comprises the innermost region to define a smooth surface to reduce and / or minimize microwave and / or radio-wave arcing within the reaction chamber 30. Arcing may occur when the breakdown voltage of a medium, such as a gas, is exceeded in a localized region with a concentrated electric field. It may be advantageous for bodies within the reaction chamber 30, and within electromagnetic wave containment structure 64 to have generally smooth geometries to prevent the accumulation of an electric field by allowing electromagnetic waves to flow freely rather than accumulate on geometries that may cause arcing. In some embodiments, the construction method of forming the portion of the functional electromagnetic wave containment structure 64 comprises providing a plurality of electromagnetic wave reflective refractory metal bodies, welding them together, thereby forming the potion of the functional electromagnetic wave containment structure 64. In other embodiments, the construction method of forming the portion of the functional electromagnetic wave containment structure 64 comprises providing a plurality of electromagnetic wave reflective refractory metal and fastening them together, thereby forming the portion of the functional electromagnetic wave containment structure 64. In other embodiments, the construction method of forming the portion of the functional electromagnetic wave containment structure 64 comprises providing a plurality of electromagnetic wave reflective refractory metal and brazing them together, thereby forming the portion of the functional electromagnetic wave containment structure 64. In other embodiments, theconstruction method of forming the portion of the functional electromagnetic wave containment structure 64 comprises providing a plurality of electromagnetic wave reflective refractory metal and riveting them together, thereby forming the portion of the functional electromagnetic wave containment structure 64. Selection of welding, fastening, brazing and / or riveting as the construction method is dependent on the material being constructed as would be known to one of skill in the art. Welding, fastening, brazing and / or riveting are preferred means of construction as they reduce hydrogen gas and other reaction participants from being able to pass between the bodies of multi region zone 60.

[0092] In preferred embodiments, the functional portion of the electromagnetic wave containment structure 64 is lowered into the reactor vessel 20 and subsequently secured by the addition of the top of the multi region zone 60.

[0093] As used herein, the term “refractory blanket” refers to, unless otherwise stated, a thermal blanket and / or thermal paper. Examples of refractory blanket materials include, but are not limited to, MAFTEC™ Blanket, Denka Alcen™ Blanket, Cerablanket™, Cerachem™ Blanket, and Kaowool™ Papers. In some preferred embodiments, a refractory blanket means a thermal blanket. In some preferred embodiments, a refractory blanket means thermal paper.

[0094] In some embodiments, the thermal containment structure 66 is comprised of one or more solid refractory material portions and / or one or more gaseous portions. The at least one solid refractory material and / or gas may be arranged to form at least one section. In some embodiments, there is a plurality of solid refractory material portions and / or a plurality of gaseous portions, arranged in a plurality of sections and / or alternative configurations.

[0095] The thermal containment structure 66 functions to thermally insulate the reaction chamber 30. In embodiments where the thermal containment structure 66 comprises a solid refractory material, the solid refractory material may be a cast solid refractory material. Such a cast solid refractory material may be cast into bricks and then the bricks placed into the reactor vessel 20 or may be poured into the reactor vessel 20 directly so as to be cast into a form defined by a shape of a structure in the reactor vessel 20 that it is cast into. The cast solid refractory material may have a melting pointabove 1500 °C. In other embodiments, the cast solid refractory material has a melting point above 1800 °C. In other embodiments still, the cast solid refractory material has a melting point above 2000 °C. In other preferred embodiments the cast solid refractory material has a melting point above 2500 °C. In some embodiments, the cast solid refractory material has a thermal conductivity less than or equal to 15 BTU / h / sq ft / °F / in at 1000 °C, less than or equal to 14 BTU / h / sq ft / °F / in at 1000 °C, less than or equal to 13 BTU / h / sq ft / °F / in at 1000 °C, less than or equal to 12 BTU / h / sq ft / °F / in at 1000 °C, less than or equal to 11 BTU / h / sq ft / °F / in at 1000 °C, less than or equal to 10 BTU / h / sq ft / °F / in at 1000 °C, less than or equal to 9 BTU / h / sq ft / °F / in at 1000 °C, less than or equal to 8 BTU / h / sq ft / °F / in at 1000 °C, less than or equal to 7 BTU / h / sq ft / °F / in at 1000 °C, less than or equal to 6 BTU / h / sq ft / °F / in at 1000 °C, less than or equal to 5 BTU / h / sq ft / °F / in at 1000 °C, less than or equal to 4 BTU / h / sq ft / °F / in at 1000 °C. or less than or equal to 3 BTU / h / sq ft / °F / in at 1000 °C. In preferred embodiments, the cast solid refractory material has a thermal conductivity less than or equal to 6 BTU / h / sq ft / °F / in at 1000 °C. In other preferred embodiments, the cast solid refractory material has a thermal conductivity less than or equal to 5 BTU / h / sq ft / °F / in at 1000 °C.

[0096] In some embodiments, the solid refractory material comprises one or more refractory blanket materials. In embodiments where the thermal containment structure 66 comprises a refractory blanket material, the refractory blanket material has a melting point above 1500 °C, above 1700 °C, above 2000 °C or above 2500 °C. In some embodiments, the refractory blanket material has a thermal conductivity less than or equal to 1 .5 BTU / h / sq ft / °F / in at 1000 °C, less than or equal to 1 BTU / h / sq ft / °F / in at 1000 °C, less than or equal to 0.75 BTU / h / sq ft / °F / in at 1000 °C, less than or equal to 0.5 BTU / h / sq ft / °F / in at 1000 °C, less than or equal to 0.3 BTU / h / sq ft / °F / in at 1000 °C, less than or equal to 0.2 BTU / h / sq ft / °F / in at 1000 °C. In preferred embodiments, the refractory blanket material has a thermal conductivity less than or equal to 1 BTU / h / sq ft / °F / in at 1000 °C. In other preferred embodiments, the refractory blanket material has a thermal conductivity less than or equal to 0.5 BTU / h / sq ft / °F / in at 1000 °C.

[0097] In some embodiments, the thermal containment structure 66 comprises a refractory blanket material and a cast solid refractory material. The refractory blanket material has a lower density than the cast solid refractory material. In someembodiments, the thermal containment structure 66 comprises two different refractory blanket materials. In embodiments with a first refractory blanket material with comparatively higher silica content, and a second refractory blanket material with comparatively lower silica content, it is preferable that the first refractory blanket material with comparatively higher silica content is situated more distally from the reaction chamber 30 than the second refractory blanket material, in order to reduce and / or minimize process species interaction with silica.

[0098] In some embodiments, the cast solid refractory material or refractory blanket material comprises a material that comprises oxide compounds such as aluminum oxide, iron oxide, calcium oxide, magnesium oxide, silicon dioxide, titanium dioxide and any combination. In some embodiments, the cast solid refractory material comprises a material selected from the group consisting of Blazelite™, Blazelite 80™, Kast-o-lite 97 L plus™, Delta T Crete™, GreenCast94™, MAFTEC™ Blanket, Denka Alcen™ Blanket, Cerablanket™, Cerachem™ Blanket, Kaowool™ Papers, and any combination thereof. These trademarks are known to people of skill in the art and are referenced as of October 1 , 2024. Generally, these materials are alumina-based refractory materials. More specifically, the details of these materials may be found on the data sheets for these products, for which references are provided in Table 1 below.

[0099] Alternatively, in embodiments where at least a portion of the thermal containment structure 66 is made from a gas, the gas is typically an inert gas, and more preferably the gas does not contain oxygen. In preferred embodiments where at least one portion of the thermal containment structure 66 is made from gas, the gas is nitrogen. In some preferred embodiments, at least one portion of the thermal containment structure 66 is made from at least one gas, the at least one gas typically comprises an inert gas to prevent combustion in the event that reactive gaseous species enter the thermal containment structure 66 from the reaction chamber 30 during operation. Further, in some preferred embodiments where at least a portion of the thermal containment structure 66 is made from a gas, the gas is an inert gas that does not contain oxygen in order to protect bodies comprised within electromagnetic wave containment structure 64 from oxidation.

[0100] The thermal containment structure 66 is also often suitable for protecting the structural structure 68 from high temperatures. In this regard, if the reactor needs to be ramped down and / or shut off, for example to perform maintenance on the reactor, cooler and / or or cold air may be passed through one or more of the portions of the thermal containment structure 66 that are made from gas during operation of the reactor. Such cold and / or cooler air often contains oxygen and / or other non-inert and / or inert gases.

[0101] Further, the thermal containment structure 66 may often be suitable for reducing the thermal energy of any reactants and / or products that escape the reaction chamber 30.

[0102] Various different materials may be used in the thermal containment structure 66 and may be arranged depending on their structural and thermal containment properties. In some embodiments, materials with lower thermal conductivity are located nearest to the reaction chamber 30 in order to reduce heat loss from the reaction chamber 30, andto limit thermal transfer to other materials in the reactor vessel 20, including the other portions of the thermal containment structure 66.

[0103] In some embodiments, the thermal containment structure 66 comprises a plurality of cast solid refractory material sections, located toward the bottom of the reaction chamber 30. The shape of the cast solid refractory material sections is determined by the shape of the structure in the reactor vessel 20 that it is cast into. In some embodiments, the cast solid refractory material sections are generally cylindrical in shape. The cast solid refractory material sections may be supported by the electromagnetic wave containment structure 64, the structural structure 68, by other sections of the thermal containment structure 66, or any combination of structures 64, 66, and / or 68.

[0104] In some embodiments, the thermal containment structure 66 comprises a section of gas, nearest to an outermost layer of the electromagnetic wave containment structure 64, and a section of refractory blanket material, further from the outermost layer of the electromagnetic wave containment structure 64. The refractory blanket material may be attached to the structural structure 68 by any attachment means known to one of skill in the art. In some embodiments, a section of refractor blanket material sits on the structural structure 68. In some embodiments, prongs are attached to the inside of the structural structure 68 to attach the refractory blanket material to the structural structure 68.

[0105] The thermal containment structure 66 may also reduce gas leakage from reaction chamber 30. In some embodiments, the thermal containment structure 66 decreases leakage of reactant products from the innermost region by providing a gas at a pressure higher than the pressure in the reaction chamber 30. In order to provide this higher pressure, a purge gas may be used. The purge gas will preferably be an inert gas. The purge gas may be nitrogen, argon, hydrogen or any other purge gas known to one of skill in the art. In some embodiments, the purge gas may be nitrogen, hydrogen or any other purge gas known to one of skill in the art. In some other embodiments, the purge gas may be a reactant gas that is being heated prior to introduction into the reaction chamber 30. In some embodiments, the thermal containment structure 66 is shaped such that the purge gas does not enter the reaction chamber 30 from thethermal containment structure 66. In some embodiments, various sealing means known to the person of skill in the art will be used to limit leakage of the purge gas from the thermal containment structure 66 into the reaction chamber 30, or through the structural structure 68. For example, gaskets and packing may be located between the thermal containment structure 66 and the structural structure 68 and / or between the thermal containment structure 66 and the electromagnetic wave containment structure 64.

[0106] Gases from within the reaction chamber 30 generally do not flow through the thermal containment structure 66. The thermal containment structure 66 is often not permeable to, or at least not very permeable to gases and often comprises materials that are not porous. Hence, most gases cannot flow through or cannot easily flow through this layer. When the thermal containment structure 66 comprises materials that are porous, a purge gas may be introduced to the pores to reduce leaking of gases from the reaction chamber 30. Due to its size, hydrogen gas has the potential to leak through the atomic structure of this layer but only very minimally.

[0107] In one embodiment, at the top of reactor vessel 20, the thermal containment structure 66 may be secured to the structural structure 68 using any means known to one of skill in the art, such as attachment using anchors. In certain embodiments the thermal containment structure 66 is supported by the bottom of the structural structure 68, wherein said support is through a physical connection such as a bolt, interference fit or another connection element known to one of skill in the art. In preferred embodiments, the connection means between the thermal containment structure 66 and the electromagnetic wave containment structure 64 and / or between the thermal containment structure 66 and the structural structure 68 are selected to allow for thermal expansion. Such allowance for thermal expansion may be achieved by providing gaps between bodies within and / or between each of the three functional structures. In other embodiments, allowance for thermal expansion is provided by compressible elements, such as compressible materials and / or springs.

[0108] In some embodiments, the thermal containment structure 66 is made from insulating materials and / or refractory materials. Such materials may be solids, liquids, gases, or combinations thereof. Such solid materials may include materials that have a low to no silica (SiO2) content as well as a low to no iron content. In a preferredembodiment, the thermal containment structure 66 has a silica content of less than 2.5%. In a preferred embodiment, the thermal containment structure 66 has a silica content of less than 0.3%. It may be advantageous to reduce and / or minimize the silica content in the thermal containment structure 66 because silica can interact with reaction species and cause the formation of water vapor at reaction conditions which may interfere with the functioning of the structures within reactor vessel 20. In some embodiments, the thermal containment structure 66 is made from a Blazelite™ material, such as Blazelite™ 80. In some embodiments, the thermal containment structure 66 comprises a gas, such as natural gas, methane, nitrogen, argon, and / or other gases, flowing past the solid material of the thermal containment structure 66. In some embodiments, the thermal containment structure 66 comprises a gas, such as natural gas, methane, nitrogen, and / or other gases, flowing past the solid material of the thermal containment structure 66. In some embodiments, the thermal containment structure 66 extends around the entire innermost region. In other embodiments, the thermal containment structure 66 only extends around a portion of the innermost region. In some embodiments, the thermal containment structure 66 extends around a portion of the innermost region and is also a part of the innermost region.

[0109] The thermal containment structure 66 helps to reduce the energy required to maintain a higher temperature inside the reaction chamber 30 and also helps to maintain a lower temperature of the structural structure 68. In some embodiments, the thermal containment structure 66 is used to preheat the inlet 50 to reduce the energy requirement of heat exchanger 160.

[0110] The structural structure 68, providing mechanical strength, may be made of any material provided that it is strong and not brittle. Often the structural structure 68 is made from stainless steel or another type of steel. The structural structure 68 is also impermeable to gases, thereby reducing leaks from the reactor vessel 20.

[0111] In a particular embodiment, the electromagnetic wave containment structure 64 may be connected to the thermal containment structure 66 using any manner of connection known to the person of skill in the art. In other embodiments, the electromagnetic wave containment structure 64 may be connected to the structuralstructure 68 using any manner of connection known to a person of skill in the art, such as attachment using anchors.

[0112] In some embodiments, the thermal containment structure 66 may be connected to the structural structure 68 using any manner of connection known to a person of skill in the art, such as attachment using anchors.

[0113] Of consideration, when connecting the electromagnetic wave containment structure 64 and the thermal containment structure 66 is that electromagnetic wave containment structure 64 is likely to undergo significantly more thermal expansion than the thermal containment structure 66, and if the reactor is to be used at high temperatures, then such thermal expansion should be considered when constructing the connection between the electromagnetic wave containment structure 64 and the thermal containment structure 66. This is also of consideration when connecting the electromagnetic wave containment structure 64 and the structural structure 68.

[0114] Of consideration, when connecting the thermal containment structure 66 and the structural structure 68 is that thermal containment structure 66 is likely to undergo significantly more thermal expansion than the structural structure 68, and if the reactor is to be used at high temperatures, then such thermal expansion should be considered when constructing the connection between the thermal containment structure 66 and the structural structure 68. Such additional thermal expansion of the thermal containment structure 66 may be due to the proximity of the thermal containment structure 66 to the reaction chamber 30.

[0115] If the reactor is to be used at high temperatures, then thermal expansion of the reactor vessel 20 must be considered. Reactor components may undergo high stress and damage if not designed to accommodate for thermal expansion. Thermal expansion of materials may occur radially and / or axially. It should also be considered that thermal expansion impacts different materials to various extents due to differing material properties and the degree of exposure to high temperatures. For this reason, the electromagnetic wave containment structure 64 is likely to undergo more thermal expansion than the thermal containment structure 66. In certain embodiments, the structures of the multi region zone 60 are separated by a thermal expansion gap comprising gases to accommodate for radial thermal expansion during high temperatureoperation. In certain embodiments, the thermal expansion gap may be at least 0.5mm, at least 1 mm, at least 2mm, at least 3mm or at least 4mm wide. In some embodiments, the thermal expansion gap may be at least 0.5 inches, at least 1 inch, or at least 2 inches wide. In some embodiments there is a plurality of thermal expansion gaps, and the thermal expansion gaps are of different sizes. In some embodiments, the thermal expansion gaps between two elements of the multi region zone 60 will be different at different locations within the multi region zone 60. For instance, the thermal expansion gap may be larger at the bottom of the reactor and relatively smaller at the top of the reactor to account for temperature profiles in the reaction chamber 30. In certain embodiments, the regions of the multi region zone 60 comprise additional solid materials to accommodate thermal expansion, where the solid materials may be thin refractory insulation materials known to those of skill in the art, such as ceramic wool or paper insulation. In embodiments where electromagnetic wave containment structure 64 comprises multiple solid layers, the layers may be separated from one another by thermal expansion gaps comprising gases to account for thermal expansion. In some embodiments, the structures of the multi region zone 60 may comprise additional structures to accommodate thermal expansion. The placement of the outlet 70 within the reactor vessel 20 must also accommodate thermal expansion. In some embodiments, the outlet 70 is located at the side of the reactor vessel 20. In preferred embodiments, the outlet 70 is located at the top or at the bottom of the reactor vessel 20 to accommodate radial thermal expansion of the multi region zone 60.

[0116] The structural structure 68 may be connected to the thermal containment structure 66, or the structural structure 68 may not be connected to the thermal containment structure 66. In embodiments where the structural structure 68 is connected to the thermal containment structure 66, the connection may be done using any connection manner known to a person of skill in the art. For example, anchors may be provided on the structural structure 68, which anchors can be embedded into the thermal containment structure 66. In another embodiment, the thermal containment structure 66 may sit between the electromagnetic wave containment structure 64 and the structural structure 68. In some embodiments, the thermal containment structure 66 is in direct physical contact with the electromagnetic wave containment structure 64and / or the structural structure 68. In other embodiments, the thermal containment structure 66 is not in direct physical contact with the electromagnetic wave containment structure 64 and / or the structural structure 68.

[0117] In some embodiments, the structural structure 68 may be connected to the electromagnetic wave containment structure 64 using any connection manner known to a person of skill in the art. For example, anchors may be provided on the structural structure 68, which anchors can be embedded into the electromagnetic wave containment structure 64. In other embodiments, the electromagnetic wave containment structure 64 defines a complex shape, with portions of the shape extending toward the outer region and providing a physical connection means to the outer region.

[0118] The inlet 50 passes through the multi region zone 60 and is operable to allow reactants and / or other reaction participants (e.g. purging gases, heating and / or cooling materials, catalysts, etc.) to enter into the reaction chamber 30 from outside the reactor vessel 20. In some embodiments, there is only a single inlet 50. In some other embodiments, a single inlet 50 is adapted to combine multiple sources of reactants and / or reactant participants to merge so that the single inlet 50 is the point of entry into the reaction chamber 30 for all reactants and / or reaction participants. In such embodiments, reactants and / or reaction participants may be introduced into the reaction chamber 30 individually or alternatively introduced into the reaction chamber 30 collectively. In some other embodiments, there is more than one inlets 50, each of the more than one inlets 50 is independently operable to introduce at least one reactant and / or other reaction participant into the reaction chamber 30. Often the inlet 50 is operable to introduce gaseous hydrocarbon to the reaction chamber 30. Often the inlet 50 is operable to introduce both gaseous hydrocarbon and solid carbon to the reaction chamber 30. In some particular embodiments there are two inlets 50, one for introducing gaseous hydrocarbon and another for introducing solid carbon into the reaction chamber 30.

[0119] A source 150 introduces a reactant and / or reaction participant to the inlet 50. In some embodiments, the source 150 directly introduces the reactant and / or reaction participant to the inlet 50. In some other embodiments, the source 150 provides thereactant and / or reaction participant to a heat exchanger 160, prior to introducing the reactant and / or reaction participant to the inlet 50.

[0120] Reaction of the reactants and / or participation of the reaction participants occurs in the reaction chamber 30. Often such reaction and / or participation results in reaction products. Reaction products may be removed from the reaction chamber 30 via the at least one outlet 70. In some embodiments, there is only one outlet 70 and outlet 70 is adapted to further separate, if required, the various different products formed in the reaction chamber 30. In some other embodiments, there are more than one outlets 70, each of the more than one outlets 70 being suitable for removing one or more of the products formed in the reaction chamber 30. In some other embodiments still, there is more than one outlets 70, each outlet 70 being adapted to collect a specific phase (e.g. gas, liquid, or solid) and operable to separate, if required, each of the products of the same phase from each other. Once suitably separated, the products are then collected in capture containers. Often there is a capture container for each phase to be captured, such as a gas product capture container 80 and / or a solid product capture container 90. When captured in phases, the separate products in each phase may be separated after capture, if required.

[0121] Often products being removed from the reaction chamber 30 are hot. In some embodiments, one or more of such hot products are removed from the reaction chamber 30 and then introduced to the heat exchanger 160 where the heat of the product is reduced and transferred to a reactant and / or reaction participant that is about to enter the reaction chamber 30 via inlet 50 so that the reactant and / or reaction participant is at a higher temperature when entering the reaction chamber 30. The cooled products are now more suitable for further processing, such as for introduction into a separator where products may be better separated, and / or for introduction into a capture container. Cooling can also be achieved by any other method known to a person skilled in the art, such as a chiller.

[0122] The inlets 50 and outlets 70 are in fluid communication with the reaction chamber 30 and protrude through the multi region zone 60 and into the reaction chamber 30. In certain embodiments, the outlets 70 comprise surface structures to reduce microwave leakage beyond the reaction chamber 30, such as microwave choke structures.Further, individual components of the electromagnetic wave containment structure 64 are often composed of multiple pieces of the same material. To join these materials, it is necessary to adequately seal the connections between (a) the inlets 50 and the electromagnetic wave containment structure 64; (b) the outlets 70 and the electromagnetic wave containment structure 64; (c) the connection means 110 and the electromagnetic wave containment structure 64; and (d) the multiple pieces of the electromagnetic wave containment structure 64. Suitable joining techniques include any joining technique known to a person of skill in the art, including interference fits, welding, bolts, brazing, spraying, and / or riveting. The properties of the materials being joined and reduction of electromagnetic wave and gaseous species leakage must be considered when selecting a joining technique. In some embodiments, the inlets 50 and / or the outlets 70 are formed contiguously with the multi region zone 60 and as such are part of the multi region zone 60. In these latter embodiments, the inlets 50 and outlets 70 have the same electromagnetic wave containment structure, thermal containment structure, and structural structure configuration as the multi region zone 60 and sealing the inlets 50 and outlets 70 to the sources 150 and capture containers may also be achieved using any technique known to a person of skill in the art, such as welding and / or riveting. In some embodiments, the inlets 50 and / or outlets 70 are not formed contiguously with multi region zone 60. In such embodiments, additional components for connection and sealing are required. The inlets 50 and outlets 70 may comprise electromagnetic wave sealing means to prevent microwave leakage from reaction chamber 30. Further, connection means 110 may comprise electromagnetic wave sealing means to prevent microwave leakage. The electromagnetic wave sealing means may be gaskets, electromagnetic chokes, or any other sealing means known to one of skill in the art. The gaskets or other sealing means must be constructed of materials that can withstand high temperatures, such as refractory materials. The gaskets may have any type of structural property known to one of skill in the art.

[0123] In the embodiments illustrated in the Figures, all of sections and surfaces 400, 405, 410, 420, 430, 435, 440, 450, 460, 470, 480, and 490 together make up the electromagnetic wave containment structure 64 and function to reduce and / or prevent electromagnetic waves from escaping the reaction chamber 30. Further, many of thesesections cooperate to maintain higher levels of electromagnetic waves in the reaction chamber 30.

[0124] In the embodiments illustrated in the Figures, all of sections, portions, and surfaces 610, 620, 630, 640, 650, 655 together make up the thermal containment structure 66 and function to thermally insulate the reaction chamber 30. Many of these sections may also cooperate to perform other functions, such as reducing thermal transfer to other portions of the reactor vessel 20.

[0125] Referring to Figure 3, there is an embodiment of the reactor vessel 20 shown generally at 300. Section A, at the top of the reactor vessel 20, is shown in more detail in Figure 4. Section B, at the bottom of the reactor vessel 20, is shown in more detail in Figure 6. Figure 3 also shows the gross relative positioning of the reaction chamber 30, the electromagnetic wave containment structure 64, the thermal containment structure 66, and the structural structure 68. For each of the structures 64, 66, and 68, there are multiple distinct structures and in some cases those structures are not physically connected to each other and in other cases they are physically connected to each other. For example, the lowermost portion of the thermal containment structure 66 is not connected to the other portions of the thermal containment structure 66 as illustrated in Figure 3.

[0126] Referring now to Figure 4, the electromagnetic wave containment structure 64 comprises four discrete sections, 400, 410, 420, and 430. Sections 400 and 410 may be a single body or may be two or more bodies connected at section 440. When they are two or more bodies, they may connect as described herein, for example using welding, fastening, brazing and / or riveting. Each of sections 400 and 410 may independently be a single body or a plurality of bodies. Similarly, sections 420 and 430 may be a single body, or may be two or more bodies similarly connected at section 450. Each of sections 420 and 430 may independently be a single body or a plurality of bodies. All of these bodies may be made of the same material or may be made of different materials, provided that they are all materials suitable for use for the electromagnetic wave containment structure 64, as described above.

[0127] Section 400 is the innermost region of the electromagnetic wave containment structure 64. One surface of section 400, surface 405, is a smooth surface that defines,at least in part, the reaction chamber 30. The surface 405 is smooth so that the electromagnetic waves are adequately contained and do not arc during operation of the reactor vessel 20. Further, the smoothness of the surface 405 also reduces depositing of process species on the surface 405. Section 410 is often perpendicular or generally perpendicular to section 400 and is on top of section 400 and protrudes outwardly and away from the reaction chamber 30 from the section 440 between sections 400 and 410.

[0128] Sections 420 and 430 comprise the outermost region of the electromagnetic wave containment structure 64. Section 420 is on top of section 430 and protrudes outwardly and away from reaction chamber 30 from the section 450 between sections 420 and 430. Section 420 is often perpendicular or generally perpendicular to section 430. Section 430, at surface 435, interacts with section 650 of the thermal containment structure 66. In some embodiments, surface 435 supports the thermal containment structure 66 and acts as an anchor to maintain the relative position of this portion of the thermal containment structure 66.

[0129] Sections 410 and 420 are often parallel to each other and contact each other through smooth surfaces that create friction with each other. Section 410 is on top of section 420 but offset from each other such that section 420 is closer to the outermost section of the reactor vessel 20 when compared to section 410. The offset of these two sections defines a gap between sections 400 and 430. This gap is a section 640 of the thermal containment structure 66 and facilitates proper functioning of the reactor vessel 20 when the materials of sections 400 and 430 expand due to thermal expansion. Similarly, the smooth surfaces of sections 410 and 420 that contact each other permit for small movements of these surfaces relative to each other to accommodate thermal expansion. Nevertheless, it is important that connecting surfaces of sections 410 and 420 are connected in a tight fit in order to reduce electromagnetic waves and / or process species from leaking from the reaction chamber 30.

[0130] Often a portion of the structural structure 68 engages with section 410 to ensure a tight connection between sections 410 and 420. In some other embodiments, the structural structure 68 engages with both sections 410 and 420 to ensure a tight connection between sections 410 and 420. In some other embodiments still, section420 engages with the thermal containment structure 66 to ensure a tight connection between sections 410 and 420. In some other embodiments still, the structural structure 68 engages with section 410 and the thermal containment structure 66 engages with section 420 to ensure a tight connection between sections 410 and 420. In some preferred embodiments, the structural structure 68 engages with both sections 410 and 420 and the thermal containment structure 66 also engages with section 420 to ensure a tight connection between sections 410 and 420.

[0131] Referring to Figure 4, the thermal containment structure 66 comprises two discrete sections, 640 and 650. Each of sections 640 and 650 may each independently be a single body or a plurality of bodies. All of these bodies may be made of the same material or may be made of different materials, provided that they are all materials suitable for use for the thermal containment structure 66, as described above. Sections 640 and 650 are often parallel to each other.

[0132] Section 640 is the innermost middle region of the thermal containment structure 66. Section 640, interacts with the electromagnetic wave containment structure 64. Section 640 often comprises a gaseous body, and section 640 is contained in a gap which is defined by sections 400, and 410, as well as 420 and 430, the innermost region of the electromagnetic wave containment structure 64 and the outermost region of the electromagnetic wave containment structure 64, respectively.

[0133] Section 650 is the outermost middle region of the thermal containment structure 66. Section 650, at surface 655, interacts with the structural structure 68. Section 650 may comprise one or more refractory blanket materials.

[0134] In some embodiments, surface 435 of electromagnetic wave containment structure 64 section 430 supports the thermal containment structure 66 and acts as an anchor to maintain the relative position of section 650 of the thermal containment structure 66. In some other embodiments, surface 655 supports the thermal containment structure 66 and acts as an anchor to maintain the relative position of section 650 of the thermal containment structure 66.

[0135] Referring now to Figure 5, the electromagnetic wave containment structure 64 also comprises a top section 460 and a bottom section 470. The top section 460 may also define, at least in part, the reaction chamber 30. Section 460 also supports a topportion of the thermal containment structure 66. In some embodiments, section 460 is a discrete section of the electromagnetic wave containment structure. In other embodiments, section 460 is contiguous with section 410. In some embodiments, section 460 is a single body, and in other embodiments, section 460 is a plurality of bodies. When it is a plurality of bodies, the plurality of bodies may be connected as described herein, for example using welding, fastening, brazing, and / or riveting. All of these bodies may be made of the same material or may be made of different materials, provided that they are all materials suitable for use for the electromagnetic wave containment structure 64, as described above. When section 460 is contiguous with section 410, then the two sections may comprise a single body or may comprise a plurality of bodies connected as described herein, for example using welding, fastening, brazing and / or riveting. All of these bodies may be made of the same material or may be made of different materials, provided that they are all materials suitable for use for the electromagnetic wave containment structure 64, as described above.

[0136] When section 460 is a discrete section of the electromagnetic wave structure, it is in contact with section 410 through a tight fit causing friction between sections 460 and 410. Often a portion of the structural structure 68 engages with section 460 to ensure a tight connection between sections 410 and 460. In some other embodiments, the structural structure 68 engages with both sections 410 and 460 to ensure a tight connection between sections 410 and 460. In some other embodiments still, section 460 engages with the thermal containment structure 66 to ensure a tight connection between sections 410 and 460. In some other embodiments still, the structural structure 68 engages with section 410, and the thermal containment structure 66 engages with section 460 to ensure a tight connection between sections 410 and 460. In some preferred embodiments, the structural structure 68 engages with both sections 410 and 460, and the thermal containment structure 66 also engages with section 460 to ensure a tight connection between sections 410 and 460. A tight connection between sections 410 and 460 reduces leakage from reaction chamber 30. Further, the tight connection also accommodates thermal expansion, provided that the contacting surfaces are smooth and generally parallel to each other.

[0137] Section 470 is physically separate from all of the other portions of theelectromagnetic wave containment structure 64. Section 470 supports a first bottom thermal containment portion 610 of the thermal containment structure 66 and reduces electromagnetic wave leakage from the reactor vessel 20. Section 470 is often not in direct contact with the reaction chamber 30. Section 470 may be a single body or may comprise a plurality of bodies connected as described herein, for example using welding, fastening, brazing and / or riveting. All of these bodies may be made of the same material or may be made of different materials, provided that they are all materials suitable for use for the electromagnetic wave containment structure 64, as described above.

[0138] Referring to Figure 5, the thermal containment structure 66 also comprises a first bottom thermal containment portion 610, a second bottom thermal containment portion 620, and a top thermal containment portion 630.

[0139] The first bottom thermal containment portion 610 of the thermal containment structure 66 may be located below the reaction chamber 30. In some embodiments, the first bottom thermal containment portion 610 is cast into a structure in the reactor vessel 20 and its shape is determined by the structure it is cast into. The first bottom thermal containment portion 610 is often generally cylindrical in shape, and in some embodiments, is supported by a portion of the electromagnetic wave containment structure 64. One or a plurality of openings as defined by the first bottom thermal containment portion 610 may permit access to the reaction chamber 30, for example to accommodate the inlet 50 and / or the outlet 70.

[0140] The second bottom thermal containment portion 620 is located distally from the center of the reaction chamber 30. The second bottom thermal containment portion 620 is adjacent to a portion of a structural structure 68, and may be attached to the portion of the structural structure 68 with anchors, a bolt, prongs or any attachment means known to one of skill in the art. In preferred embodiments, attachment means are selected to accommodate thermal expansion, as described herein.

[0141] The top thermal containment portion 630 is supported by section 460 of the electromagnetic wave containment structure 64. In some embodiments, the top thermal containment portion 630 is cast into a structure in the reactor vessel 20 and its shape is determined by the structure it is cast into. The top thermal containment portion 630 isoften generally cylindrical in shape, and in some embodiments, is supported by a portion of the electromagnetic wave containment structure 64. One or a plurality of openings as defined by the top thermal containment portion 630 may permit access to the reaction chamber 30, for example to accommodate the inlet 50 and / or the outlet 70.

[0142] Referring now to Figure 6, the bottom section of the electromagnetic wave containment structure 64 is comprised of sections 400, 430, 470, 480 and 490. In some embodiments, section 480 is a discrete section of the electromagnetic wave containment structure. In other embodiments, section 480 is contiguous with section 430. In some embodiments, section 480 is a single body, and in other embodiments, section 480 is a plurality of bodies. When it is a plurality of bodies, the plurality of bodies may be connected as described herein, for example using welding, fastening, brazing, and / or riveting. All of these bodies may be made of the same material or may be made of different materials, provided that they are all materials suitable for use for the electromagnetic wave containment structure 64, as described above. When section 480 is contiguous with section 430, then the two sections may comprise a single body or may comprise a plurality of bodies connected as described herein, for example using welding, fastening, brazing and / or riveting. All of these bodies may be made of the same material or may be made of different materials, provided that they are all materials suitable for use for the electromagnetic wave containment structure 64, as described above.

[0143] Similarly, in some embodiments, section 490 is a discrete section of the electromagnetic wave containment structure. In other embodiments, section 490 is contiguous with section 480. In some embodiments, section 490 is a single body and in other embodiments section 490 is a plurality of bodies. When it is a plurality of bodies, the plurality of bodies may be connected as described herein, for example using welding, fastening, brazing, and / or riveting. All of these bodies may be made of the same material or may be made of different materials, provided that they are all materials suitable for use for the electromagnetic wave containment structure 64, as described above. When section 490 is contiguous with section 480, then the two sections may comprise a single body or may comprise a plurality of bodies connected as described herein, for example using welding, fastening, brazing and / or riveting. All of these bodiesmay be made of the same material or may be made of different materials, provided that they are all materials suitable for use for the electromagnetic wave containment structure 64, as described above.

[0144] In some embodiments, sections 480 and 430 are contiguous with each other while section 490 is a discrete section. In some embodiments, sections 480 and 490 are contiguous with each other, and section 430 is discrete from the contiguous sections 480 and 490. In some other embodiments still, all of sections 430, 480, and 490 are contiguous with each other.

[0145] Section 480 is often perpendicular to or generally perpendicular to sections 400, 430, and 490 and is positioned underneath, but separate from section 400. There is a gap 402 between sections 480 and 400. This gap 402 accommodates thermal expansion of the electromagnetic wave containment structure 64. As the heat in the reaction chamber 30 increases, the electromagnetic wave containment structure heats up and expands, and the gap 402 gets smaller as section 400 approaches section 480. During some very hot operations, section 400 will contact section 480. If thermal expansion continues after contact between sections 400 and 480, then a portion of the structural structure 68 comprising one or more springs 810 are operable to compress to accommodate the continued thermal expansion.

[0146] The one or more springs 810 are connected to the lowermost portion of section 68 and are separated from the reaction chamber 30 by the section 470 of the electromagnetic wave containment structure 64 and the first bottom thermal containment portion 610 of the thermal containment structure 66. Section 470 of the electromagnetic wave containment structure 64 may be connected to one or more springs 810. The first bottom thermal containment portion 610 of the thermal containment structure 66 separating the reaction chamber 30 from the springs 810 and the lowermost portion of section 68 is on top of and connected to section 470 of the electromagnetic wave containment structure 64. As can been seen in Figure 6, one or a plurality of openings as defined by section 470 and / or first bottom thermal containment portion 610 may permit access to the reaction chamber 30, for example to accommodate the inlet 50 and / or the outlet 70.

[0147] Referring to Figure 6, the bottom of the reactor vessel 20 is shown in more detail. In this embodiment, it can be seen that section 610 of the thermal containment structure 66 is generally physically separate from the other sections of the thermal containment structure 66.

[0148] Section 610 is in fluid connection with section 640 via a gap 402. However, during operating of reactor vessel 20 at high temperatures, gap 402 may no longer be present as thermal expansion of section 400 of the electromagnetic wave containment structure 64 may close gap 402, thereby physically separating sections 610 and 640. Section 610 is often supported by a section 470 of the electromagnetic wave containment structure 64, which in turn is supported by one or more springs 810 of the structural structure 68. In some embodiments, section 610 is supported by the structural structure 68 in the absence of section 470 of the electromagnetic wave containment structure 64. Further, as can been seen in Figure 6, sections 610 and the portion of the electromagnetic wave containment structure 64 define holes and / or channels to accommodate inlets 50 and / or outlets 70.

[0149] Although various embodiments of the invention are disclosed herein, many adaptations and modifications may be made within the scope of the invention in accordance with the common general knowledge of those skilled in this art. Such modifications include the substitution of known equivalents for any aspect of the invention in order to achieve the same result in substantially the same way. Numeric ranges are inclusive of the numbers defining the range. Furthermore, numeric ranges are provided so that the range of values is recited in addition to the individual values within the recited range being specifically recited in the absence of the range. The word "comprising" is used herein as an open-ended term, substantially equivalent to the phrase "including, but not limited to", and the word "comprises" has a corresponding meaning. As used herein, the singular forms "a", "an" and "the" include plural references unless the context clearly dictates otherwise. Thus, for example, reference to "a thing" includes more than one such thing. Citation of references herein is not an admission that such references are prior art to the present invention. Furthermore, material appearing in the background section of the specification is not an admission that such material is prior art to the invention. Any priority document(s) are incorporatedherein by reference as if each individual priority document were specifically and individually indicated to be incorporated by reference herein and as though fully set forth herein. The invention includes all embodiments and variations substantially as hereinbefore described and with reference to the examples and drawings.

Claims

Claims1 . A reactor vessel comprising: a) a reaction chamber; b) a thermal containment structure, the thermal containment structure comprising at least one thermally insulating body having a high specific heat capacity and shaped to reduce thermal conductivity between structures in the reactor vessel; and c) an electromagnetic wave containment structure, the electromagnetic wave containment structure comprising at least one electromagnetic-reflective body having a high melting point and a high recrystallization point, wherein the at least one electromagnetic-reflective body is shaped with a smooth innermost surface for maintaining electromagnetic waves in the reaction chamber.

2. The reactor vessel of claim 1 wherein the at least one electromagnetic-reflective body comprises a single, closed shaped electromagnetic-reflective body having a top, a bottom, and a side.

3. The reactor vessel of claim 1 wherein the at least one electromagnetic-reflective body comprises at least two electromagnetic-reflective bodies, a first electromagnetic- reflective body having an open shape thereby forming a side and a second electromagnetic-reflective body having a flat, planar shape thereby forming a top.

4. The reactor vessel of claim 1 wherein the at least one electromagnetic-reflective body comprises a plurality of electromagnetic-reflective bodies, wherein a first plurality of electromagnetic-reflective bodies comprises an open shape thereby forming a side and a second plurality of electromagnetic-reflective bodies comprise a flat, planar shape thereby forming a top.

5. The reactor vessel of any one of claims 1 to 4 wherein the at least one thermally insulating body comprises at least one solid refractory material selected from the group consisting of: MAFTEC™ Blanket, Denka Alcen™ Blanket, Cerablanket™, Cerachem™ Blanket, and Kaowool™ Papers, Blazelite™, Blazelite 80™, Kast-o-lite 97 L plus™, Delta T Crete™, GreenCast94™, MAFTEC™ Blanket, Denka Alcen™ Blanket, Cerablanket™, Cerachem™ Blanket, Kaowool™ Papers, and any combination thereof.

6. The reactor vessel of any one of claims 1 to 5 wherein the at least one thermally insulating body comprises at least one gas selected from the group consisting of: an inert gas, nitrogen, and a mixture of gases that do not contain oxygen.

7. The reactor vessel of any one of claims 1 to 6 wherein the at least one electromagnetic-reflective body is highly electrically conductive.

8. The reactor vessel of any one of claims 1 to 7 wherein the at least one electromagnetic-reflective body is comprised of at least one material selected from the group consisting of: copper, brass, steel, stainless steel, steel alloys, nickel, chromium, aluminum, titanium, zirconium, molybdenum, tungsten, niobium, rhodium, osmium, castable refractory, and any combination thereof.

9. The reactor vessel of any one of claims 1 to 8 wherein the at least one electromagnetic-reflective body is comprised of at least one alloy selected from the group consisting of: molybdenum lanthanum oxide, titanium zirconium molybdenum, chromium aluminum molybdenum, and nickel chromium.

10. The reactor vessel of any one of claims 1 to 9 wherein the at least one electromagnetic-reflective body consists of a molybdenum lanthanum oxide alloy.11 . The reactor vessel of any one of claims 1 to 10 wherein the at least one electromagnetic-reflective body consists of a titanium zirconium molybdenum alloy.

12. The reactor vessel of any one of claims 1 to 11 wherein the at least one electromagnetic-reflective body consists of a nickel chromium alloy.

13. The reactor vessel of any one of claims 1 to 12 wherein the at least one thermally insulating body comprises a plurality of thermally insulating bodies, wherein a first plurality of thermally insulating bodies comprises a solid refractory material and a second plurality of thermally insulating bodies comprises an inert gas.

14. The reactor vessel of any one of claims 1 to 13 wherein the at least one thermally insulating body is shaped to reduce gas leakage from the reaction chamber.

15. The reactor vessel of any one of claims 1 to 14 wherein the thermal containment structure is attached at the top of the thermal containment structure to a first structural structure.

16. The reactor vessel of any one of claims 1 to 15 wherein the thermal containment structure is physically connected at the bottom of the thermal containment structure to a second structural structure.

17. The reactor vessel of any one of claims 1 to 16 wherein the at least one electromagnetic-reflective body is generally cylindrical shaped.

18. The reactor vessel of any one of claims 1 to 17 wherein the at least one electromagnetic-reflective body comprises at least one or more solid regions and at least one or more non-solid regions.

19. The reactor vessel of any one of claims 1 to 18 wherein the at least one electromagnetic-reflective body comprises at least two electromagnetic-reflective bodiesand at least two layers, wherein the at least two layers are separated by at least one thermal expansion gap.

20. A method of reducing gas leakage from the reaction chamber of any one of claims 1 to 19, the method comprising equalizing pressure between the thermal containment structure and the reaction chamber, utilizing a purging gas.

21. The method of claim 20, wherein the purging gas is selected from the group consisting of: an inert gas, nitrogen, product gas, and a reactant gas.

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