Plasma Reactor Inlet Shielding for Carbon Deposit Prevention
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Solution Overview
Problem
Existing plasma reactors face issues with carbon deposits at hydrocarbon fluid inlets, leading to clogging and inefficient production of H2/C aerosol, along with high thermal stress on reactor components due to hot hydrogen accumulation and large reactor sizes.
Innovation Solution
The plasma reactor design features hydrocarbon fluid inlets positioned near the base of the plasma burner, with a high flow rate and direction away from the inlet to prevent deposits, and uses cooled inlet channels and tubular electrodes to shield from radiant heat, while operating at elevated pressures to enhance throughput and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If hydrocarbon fluid inlets are positioned far from the plasma to prevent carbon deposits, then deposit formation is reduced, but reactor chamber size increases and unused free space increases
Solution Approach 1:
The inlet channels are equipped with cooling means (cooling channels with coolant flow) to create localized cooling zones at the inlet positions. This allows the inlets to be positioned closer to the plasma while preventing carbon deposits through active cooling rather than relying on distance alone.
Solution Approach 2:
Coolant flowing through cooling channels acts as an intermediary between the hot plasma environment and the inlet channels. The coolant absorbs heat and prevents the inlet surfaces from reaching temperatures that would cause carbon deposition, enabling closer positioning of inlets to the plasma.
2Strength
If reactor walls are positioned far from the plasma to reduce thermal load, then thermal stress is reduced, but reactor chamber size increases and heat loss increases
Solution Approach 1:
The reactor chamber is segmented into different thermal zones: a hot zone near the plasma where high temperatures are tolerable, and cooler zones near the inlets and walls where temperature is controlled. This segmentation allows optimized positioning of components based on their specific thermal requirements rather than requiring uniform distance from plasma.
Solution Approach 2:
The cooling channels with coolant flow act as thermal intermediaries, managing heat transfer from the plasma to the reactor walls. The coolant absorbs excess heat and prevents direct thermal coupling between the plasma and reactor walls, allowing closer positioning while managing thermal stress.
3Object-generated harmful factors
If high flow rate is used to prevent carbon deposits, then deposit formation is reduced, but energy consumption increases
Solution Approach 1:
The system changes the temperature parameter of the inlet channels through active cooling. By maintaining lower temperatures at the inlets, the system prevents carbon deposits without requiring excessively high flow rates. This parameter change (temperature control) allows for more energy-efficient operation while still preventing deposits.
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
This design reduces carbon particle deposits, minimizes thermal stress, and allows for a more compact, robust reactor with improved heat utilization, increasing production efficiency and reducing costs.
Implementation Method 1
a plasma 13 is formed in the vicinity of the burner part 11
Implementation Method 2
A plasma burner 7 comprising elongated electrodes
Implementation Method 3
The hydrocarbon fluid is decomposed in the absence of oxygen and at operating temperatures of up to 2000°C into hydrogen and C particles
Implementation Method 4
The inlets are shielded from the radiant heat by the body of the plasma burner because the hydrocarbon fluid inlet is arranged in the vicinity of the base part
Data Source
Figure 1~2
Figure 3~5
AI summary
In a plasma reactor (1) for decomposing a hydrocarbon fluid, the deposition of C particles is to be reduced or completely prevented. In order to achieve this object, there is described a plasma reactor (1) for decomposing a hydrocarbon fluid which comprises a reactor chamber (2) enclosed by a reactor wall (3, 3a) and having at least one hydrocarbon fluid inlet (5) and at least one outlet (15), and in addition it comprises a plasma burner (7) having at least two elongated electrodes which each have a base part (9) that is fixed to the reactor wall (3b) and a burner part (11) which projects into the reactor chamber (2) and has a free end. The hydrocarbon fluid inlet (5) opens out into the reactor chamber (2) in such a manner that a hydrocarbon fluid flowing out therefrom flows in a space between the reactor wall and the electrodes along at least one electrode to the free end (12) thereof. A high flow rate of the fluid is thereby achieved and the direction of flow of the incoming fluid is directed away from the hydrocarbon fluid inlet (5).