Arc Plasma Reactor with Segmented Catalyst Zone for CO2 Reforming

The patent replaces conventional thermal reforming mechanisms with arc plasma discharge mechanisms. The arc plasma reactor uses electrical energy to generate high-temperature plasma that directly decomposes carbon dioxide and methane, substituting the traditional thermal field with an electrical field that creates plasma. This substitution enables higher energy efficiency while maintaining high conversion rates, as the plasma provides more effective energy coupling with the reactant molecules compared to conventional thermal methods.

The patent changes the physical and chemical parameters of the reforming process by introducing arc plasma discharge. The plasma state creates extreme local temperatures and reactive species that fundamentally alter the reaction kinetics and thermodynamics. By controlling parameters such as plasma power, gas flow rates, and reactor geometry, the system achieves both high energy efficiency and high conversion rates simultaneously, resolving the traditional trade-off between these parameters.

The patent segments the reactor into distinct functional zones: an arc discharge zone for high-temperature decomposition and a catalyst zone for controlled reactions. This spatial segmentation allows the high-power arc plasma to operate at full intensity for maximum conversion rate while the catalyst is protected from direct arc exposure. The segmented design prevents catalyst abrasion and carbon powder accumulation by isolating the catalyst from the most aggressive plasma conditions.

The patent introduces an intermediary region between the arc plasma and the catalyst where the harshest plasma conditions are moderated before reaching the catalyst. This intermediary zone allows the plasma to decompose the gases while reducing the direct impact on the catalyst. The result is high conversion rate maintenance with minimized catalyst degradation and carbon powder accumulation, as the intermediary protects the catalyst from the full force of the high-power arc plasma.

The patent applies different gas injection strategies to different regions of the reactor. At the arc discharge zone, gas is injected in a manner that prioritizes arc stability, while in downstream regions, injection patterns optimize for mixing homogeneity. This local quality approach allows each zone to achieve its primary function without compromising the other, maintaining both arc stability and gas mixing homogeneity through spatially differentiated gas introduction.

The patent employs dynamic gas injection control where injection angles, flow rates, and timing are adjusted based on real-time arc conditions and reactor state. This dynamic adjustment allows the system to maintain arc stability while achieving optimal mixing homogeneity. The gas injection system responds to changing conditions, balancing the competing requirements of arc stability and gas mixing in a way that static injection systems cannot achieve.