Chemical Reactor Combustion Flame Electrical Arc Plasma
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Solution Overview
Problem
Existing methods for chemically converting materials into new substances using plasmas are energy-intensive and costly, with large and expensive equipment required, limiting their commercial viability.
Innovation Solution
A chemical reactor that superheats a combustion flame using an electrical arc to create a plasma, facilitating the conversion of a first material into a second material with a smaller footprint and reduced energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If plasma is used to convert first material into second material, then chemical conversion efficiency is improved, but energy consumption increases
Solution Approach 1:
The patent combines a combustion flame source with a plasma generation system, merging thermal energy from combustion with electrical energy for plasma creation. This hybrid approach allows the combustion flame to provide base heating while the electrical arc generates plasma for enhanced chemical conversion, reducing overall energy consumption compared to using plasma alone.
Solution Approach 2:
The combustion flame acts as an intermediary medium that transfers thermal energy to the reaction zone. The flame provides a thermal bridge between the electrical arc input and the chemical reaction process, enabling more efficient energy utilization by pre-heating reactants and maintaining reaction zone temperature.
2Productivity
If plasma is used to convert first material into second material, then chemical conversion efficiency is improved, but equipment cost increases
Solution Approach 1:
The system merges a relatively simple combustion flame generator with a plasma generation component, creating a hybrid reactor that achieves plasma-level chemical conversion efficiency without requiring a complete plasma generation system. This reduces equipment complexity and cost compared to dedicated plasma reactors.
Solution Approach 2:
The combustion flame serves dual purposes: it provides thermal energy for the chemical reaction and creates a reactive environment that enhances plasma generation efficiency. This self-service approach reduces the need for additional heating equipment and simplifies the overall system design.
3Ease of manufacture
If conventional flame burners are used to combust first material, then equipment fabrication cost is reduced, but floor space requirement increases
Solution Approach 1:
The patent nests the plasma generation system within or adjacent to the combustion flame structure, creating a compact integrated reactor. This nested configuration allows the flame and plasma zones to occupy overlapping or adjacent spatial volumes, significantly reducing the overall floor space requirement compared to separate conventional burner systems.
Solution Approach 2:
The invention transitions from a horizontal, spread-out conventional burner configuration to a more vertical or three-dimensional integrated reactor design. By stacking functional zones (combustion zone, plasma zone, reaction zone) in different spatial dimensions, the system reduces its horizontal footprint while maintaining all necessary functions.
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 method enables efficient chemical conversion of materials with lower energy costs and reduced equipment size, achieving high-temperature plasma reactions that enhance the production of target materials like sodium borohydride, while being thermodynamically favorable and economically advantageous.
Implementation Method 1
passing an electrical arc through the combustion flame to facilitate the production of the second material
Implementation Method 2
superimposes an electrical arc onto a combustion flame to superheat the combustion flame to plasma conditions
Implementation Method 3
combusting the first material to produce a combustion flame, and a resulting gas
Data Source
AI summary
A chemical reactor and method for converting a first material into a second material is disclosed and wherein the chemical reactor is provided with a feed stream of a first material which is to be converted into a second material; and wherein the first material is combusted in the chemical reactor to produce a combustion flame, and a resulting gas; and an electrical arc is provided which is passed through or superimposed upon the combustion flame and the resulting gas to facilitate the production of the second material.