Dual-Coil Plasma Torch for Uniform Fine Particle Production
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Solution Overview
Problem
Conventional fine particle production methods using thermal plasma flames face challenges in stabilizing the plasma flame against external disturbances and achieving uniform particle size, especially when increasing productivity, leading to potential flame destabilization and reduced particle uniformity.
Innovation Solution
A fine particle production apparatus and method utilizing two coils and independent high-frequency power sources to generate a thermal plasma flame, with a feedstock supply system that disperses feedstock in a particulate or slurry form and modulates the high-frequency current amplitudes to control particle size and stability, allowing for efficient production of uniform fine particles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single coil and single high frequency power source are used to generate thermal plasma flame, then the device complexity is low, but the thermal plasma flame becomes unstable and容易被 external disturbances to destabilize
Solution Approach 1:
The plasma generation system is divided into two independent subsystems: a first coil with a first high frequency power source and a second coil with a second high frequency power source. Each coil-power source pair operates independently to generate thermal plasma flames, allowing the system to maintain stability even when subjected to external disturbances. This segmentation enables redundancy and improved reliability without requiring a single complex system.
2Productivity
If the amount of feedstock supplied to thermal plasma flame is increased to improve productivity, then the productivity of fine particles increases, but the thermal plasma flame becomes unstable and may be extinguished
Solution Approach 1:
The feedstock supply is distributed to two independent thermal plasma flames generated by separate coil-power source systems. This allows the total feedstock amount to be increased for higher productivity while each individual flame processes a manageable portion, preventing flame extinction and maintaining stability.
Solution Approach 2:
The system dynamically adjusts the operation of two plasma generation subsystems to handle variable feedstock amounts. When feedstock supply is increased, both coils can be activated to share the load, maintaining flame stability while achieving higher productivity. The independent control of each subsystem allows flexible adaptation to different production requirements.
3Manufacturing precision
If conventional thermal plasma process is used with single coil system, then the device structure is simple, but the particle size uniformity of obtained fine particles is poor
Solution Approach 1:
Two independent thermal plasma flames are generated by separate coil-power source systems, each creating distinct evaporation and particle formation zones. This segmentation of the particle production process into two parallel systems enables better control over particle size distribution, achieving improved uniformity that cannot be obtained with a single flame system.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively controls particle size and achieves high productivity with excellent uniformity in particle size, stabilizing the thermal plasma flame and preventing destabilization, even with increased feedstock amounts.
Implementation Method 1
a first coil (60) surrounding a periphery of the plasma torch (14), a second coil (62) disposed under the first coil (60) and surrounding the periphery of the plasma torch (14), a first power source section (21a) supplying the first coil (60) with first high frequency current amplitude-modulated, and a second power source section (21b) supplying the second coil (62) with second high frequency current amplitude-modulated
Implementation Method 2
a plasma generation section (21) configured to generate the thermal plasma flame inside the plasma torch (14), wherein the thermal plasma flame is generated by the first power source section (21a) and the second power source section (21b)
Data Source
AI summary
Provided are a fine particle production apparatus and a fine particle production method that can control the particle sizes of fine particles, and efficiently produce a large amount of fine particles having good particle size uniformity. The present invention comprises: a raw material supply unit which supplies raw materials for fine particle production into thermal plasma flame; a plasma torch in which the thermal plasma flame is generated, and which evaporates the raw material supplied by the raw material supply unit by means of the thermal plasma flame to form a mixture in a gas phase state; and a plasma generation unit which generates thermal plasma flame inside the plasma torch. The plasma generation unit includes: a first coil which surrounds the plasma torch, a second coil which is installed below the first coil in the longitudinal direction of the plasma torch and surrounds the circumference of the plasma torch; a first power supply unit which supplies an amplitude-modulated first high-frequency current to the first coil; and a second power supply unit which supplies an amplitude-modulated second high-frequency current to the second coil. The degree of modulation of the first high-frequency current is smaller than the degree of modulation of the second high-frequency current.