Gliding-Arc Plasma Reactor for Fertilizer Production
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Solution Overview
Problem
Traditional plasma reactors used for nitrogen-based fertilizer production face challenges due to the harsh environment caused by large voltages, electric arcs, and corrosive chemicals, leading to rapid degradation of components and complex maintenance.
Innovation Solution
A durable and serviceable plasma reactor design featuring a gliding-arc configuration with reinforced electrodes and sheaths, a gas injection system, and a removable enclosure for easy maintenance, which includes a cooling system and durable materials to extend component lifespan and facilitate repairs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional plasma reactors are used for nitrogen fixation, then fertilizer production is achieved, but component degradation occurs rapidly due to harsh environment
Solution Approach 1:
The reactor is divided into modular sections with removable enclosure portions, allowing specific components to be accessed, replaced, or maintained independently without shutting down the entire system. This segmentation enables continuous operation while maintaining component reliability.
Solution Approach 2:
The patent employs non-thermal plasma parameters (low temperature, high energy density) to achieve nitrogen fixation while reducing thermal stress on components. The plasma state is maintained at temperatures suitable for chemical reactions without overheating reactor materials, thereby extending component lifespan.
2Productivity
If traditional plasma reactors operate in harsh environment, then nitrogen fixation occurs, but maintenance complexity increases
Solution Approach 1:
The enclosure is designed with removable portions that provide service access to internal components. This allows maintenance personnel to access electrodes, gas injectors, and other components without disassembling the entire reactor, significantly reducing maintenance complexity while maintaining production continuity.
Solution Approach 2:
The reactor design incorporates features that facilitate self-maintenance and easy replacement of consumable components. Standardized interfaces and modular design enable quick swaps of degraded parts, reducing the need for complex maintenance procedures and specialized intervention.
3Power
If gliding-arc reactor design is used, then plasma generation is achieved, but corrosive chemicals degrade components quickly
Solution Approach 1:
The patent utilizes materials with high corrosion resistance to construct reactor components exposed to harsh chemicals. Composite material structures combine durability with electrical conductivity requirements, protecting components from degradation by nitric acid, ozone, and nitrous oxides while maintaining plasma generation capability.
Solution Approach 2:
The sealed chamber design creates a controlled environment that limits exposure of certain components to corrosive byproducts. By managing the chemical environment and using appropriate material selection, the system reduces corrosion rates while maintaining the necessary plasma chemistry for nitrogen fixation.
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 design enhances the longevity of reactor components, simplifies maintenance, and maintains high efficiency in producing non-thermal plasma for nitrogen fixation, ensuring a long lifetime and cost-effective operation.
Implementation Method 1
a plasma arc is generated between the first electrode and the second electrode to oxidize nitrogen in the gas stream
Implementation Method 2
a plasma arc is generated between the first electrode and the second electrode
Data Source
AI summary
Aspects of the present disclosure involve a gliding-arc type plasma reactor for use in nitrogen-based fertilizer production. The plasma reactor may include a pair of electrodes oriented in a plane within an enclosure. A pair of sheaths may attach to a corresponding electrode, with each included a strike point surface oriented to face the other sheath. The electrodes may further include an inner channel through which a cooling fluid may be pumped for heat control. A gas injection system may also be included to inject a gas into the chamber for interacting with the plasma arc and may or may not include an adjustable nozzle. The nozzle may direct air flow, including the gas, at a location at which the plasma arc may occur. The device provides for a long lifetime of components within the device and easy replacement and maintenance of the components of high-wear items.