Modular Microplasma Microchannel Reactor for Scalable Ozone Generation
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Solution Overview
Problem
Conventional plasma-chemical reactors for ozone production are limited by high cost, size, weight, and complexity due to the need for high voltages and vacuum equipment, resulting in inefficient ozone conversion and maintenance issues, particularly in commercial applications.
Innovation Solution
A modular microplasma microchannel reactor system featuring a microchannel array with electrodes isolated by a dielectric, allowing for scalable and efficient ozone generation by arranging multiple modules to achieve desired throughput, with lower voltage requirements and improved durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional discharge-based systems (DBD, corona) are used for ozone production, then ozone generation capability is achieved, but system size becomes large (milliliters to hundreds of liters) and conversion efficiency remains low (15%-18%)
Solution Approach 1:
The invention divides the plasma generation process into discrete microdischarge events occurring in numerous parallel microchannels (typically 50-500 micrometers in diameter). Each microchannel acts as an independent reaction zone, allowing the system to achieve high overall conversion efficiency through the cumulative effect of many small-scale plasma reactions rather than relying on a single large reactor volume.
Solution Approach 2:
The invention transitions from macroscopic plasma discharge (single large volume) to microscopic plasma channels (numerous small volumes arranged in parallel). This dimensional shift from millimeter/centimeter scale to micrometer scale enables dramatically higher surface-to-volume ratios, allowing wall effects to dominate and achieve much higher ozone conversion efficiencies (exceeding 50% and potentially reaching 70-80%) in a compact footprint.
2Power
If electron beam systems are used for ozone production, then high energy electron generation is achieved, but high voltage requirements (tens to hundreds of kV) and vacuum equipment increase system cost and complexity
Solution Approach 1:
The invention replaces the mechanical vacuum system and high-voltage electron acceleration infrastructure with a dielectric barrier discharge system operating at atmospheric pressure. Instead of using vacuum equipment to enable electron beam generation, the system uses a dielectric barrier to sustain plasma discharge directly in atmospheric air or oxygen, eliminating the need for vacuum pumps and complex high-voltage (kV to MV range) electron acceleration equipment while achieving sufficient electron energies for ozone production through localized intense electric fields.
Solution Approach 2:
The invention changes the operating pressure parameter from vacuum (electron beam systems) to atmospheric pressure (DBD system). This parameter change fundamentally simplifies the system by eliminating vacuum equipment while maintaining the ability to generate high-energy electrons through dielectric barrier discharge. The dielectric barrier enables sustained plasma operation at atmospheric pressure, allowing oxygen feedstock to be converted to ozone without requiring vacuum conditions.
3Temperature
If dielectric barrier discharge systems are used for ozone production, then atmospheric pressure operation is achieved, but inhomogeneous plasma with streamers is produced and system sensitivity to organic impurities increases
Solution Approach 1:
The invention applies local quality by creating uniform microdischarge conditions throughout each microchannel via the dielectric barrier, which distributes the plasma generation evenly across the electrode surface. The microchannel geometry confines the plasma to controlled regions, ensuring homogeneous reaction conditions within each channel. This local uniformity, when aggregated across numerous parallel channels, produces consistent overall performance that is less sensitive to variations in feedstock quality compared to macroscopic discharge systems.
4Productivity
If conventional plasma systems are used for commercial applications, then ozone generation is achieved, but cost, size, and weight limit wider adoption
Solution Approach 1:
The invention creates a universal platform technology where the same dielectric barrier discharge microchannel reactor design can serve multiple commercial applications (water treatment, air purification, food preservation, surface sterilization). The modular microchannel array design allows the system to be scaled and configured for different ozone production requirements, making the technology adaptable across various market segments from small-scale portable devices to large-scale industrial systems, thereby expanding commercial viability.
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 system provides a scalable, cost-effective, and efficient ozone production solution with high module lifetime, reduced maintenance, and the ability to meet various ozone output demands, from small-scale applications to larger commercial needs.
Implementation Method 1
The electrodes are isolated from the microchannels by dielectric
Implementation Method 2
Plasma can be used to promote chemical reactions in liquids and gases
Implementation Method 3
Ozone can be produced when oxygen (O2) molecules are dissociated by an energy source into oxygen atoms
Implementation Method 4
Discharge based systems create high energy electrons directly within the treated gas volume via application of locally intense electric fields
Data Source
AI summary
A preferred modular microplasma microchannel reactor device includes a microchannel array arranged with respect to electrodes for generation of plasma and isolated by dielectric from the electrodes. A cover covers a central portion of the microchannel array, while leaving end portions of the microchannel array exposed. A gas inlet and product outlet are arranged to permit flow into, through and out of the microchannel array. Reactor modules of the invention include pluralities of the modular reactor devices. The reactors devices can be arranged by a housing or a frame to be in fluid communication. A system of the invention arranges pluralities of modules. Preferred module housings, frames and reactors include structural features to create alignments and connections. Preferred modules include fans to circulate feedstock and reaction product. Other reactor devices provide plasma actuation for flow.