Fluidized bed reactors for post-processing powdered carbon

Patent metadata

Field	Value
Publication number	US-11433369-B1
Application number	US-202217739397-A
Country	US
Kind code	B1
Filing date	May 9, 2022
Priority date	May 9, 2022
Publication date	Sep 6, 2022
Grant date	Sep 6, 2022

Abstract

A system for post-processing carbon powders includes a fluidized-bed reactor having an interior containing a fluidized-bed region. The system may include a gas feed source, a gas inlet value, a gas-solid separator, and an energy source coupled to the fluidized-bed reactor. Carbon nano-particulates may be loaded, in powder form, into the fluidized-bed region prior to operation. The gas feed source may output a gas-phase mixture into the interior of the fluidized-bed reactor, and the energy source may electromagnetically excite the gas-phase mixture and generate a plasma-phase mixture formed in a plasma region positioned adjacent to or within the interior of the fluidized-bed reactor. The energy source may be positioned at one or more positions relative to the gas inlet valve.

First claim

What is claimed is:

1. A system including a fluidized-bed reactor, comprising:
a gas feed source configured to flow a gas-phase mixture into an interior of the fluidized-bed reactor;
a gas inlet valve coupled with and in fluid communication with the gas feed source, the gas inlet valve configured to regulate the flow of the gas-phase mixture into the interior of the fluidized-bed reactor;
a gas-solid separator positioned upstream of the gas inlet valve within the fluidized-bed reactor;
an energy source configured to generate a plasma-phase mixture responsive to electromagnetic excitation of the gas-phase mixture, the plasma-phase mixture formed in a plasma region adjacent to or within the interior of the fluidized-bed reactor;
a powder pre-loaded into the interior of the fluidized-bed reactor, the powder including a plurality of carbon nano-particulates configured to be fluidized above the gas-solid separator responsive to the flow of the gas-phase mixture into the interior of the fluidized-bed reactor;
a pressure control assembly configured to adjust one or more of a pressure or a velocity of at least some of the plurality of carbon nano-particulates within the interior of the fluidized-bed reactor; and
an energy management apparatus external to the fluidized-bed reactor, the energy management apparatus including a matching network coupled to the energy source and configured to control energetic excitement of the gas-phase mixture via the energy source.

2. The system of claim 1 , wherein the fluidized-bed reactor is formed as an elongated tube including an outlet configured to output the gas-phase mixture and one or more gases produced in conjunction with generating the plasma-phase mixture.

3. The system of claim 1 , wherein the energy source comprises a microwave coupled plasma torch configured to operate in either a pulsed mode or a continuous mode.

4. The system of claim 3 , wherein the microwave coupled plasma torch is configured to operate at a pressure between 1 millitorr (mTorr) and 760 Torr.

5. The system of claim 4 , wherein a cross-sectional area of the fluidized-bed reactor is one of a rectangle, a square, a bell, a circle, or an oval.

6. The system of claim 3 , wherein the microwave coupled plasma torch is positioned along one or more sides of the fluidized-bed reactor.

7. The system of claim 3 , wherein the microwave coupled plasma torch is configured to disperse additional amounts of the plasma-phase mixture into the interior of the fluidized-bed reactor, the additional amounts of the plasma-phase mixture configured to energetically excite one or more of the gas-phase mixture, the plasma-phase mixture, or the plurality of carbon nano-particulates.

8. The system of claim 1 , wherein the gas-phase mixture is configured to prevent an escape of the carbon nano-particulates from the fluidized-bed reactor.

9. The system of claim 1 , further comprising:
a side port formed in the fluidized-bed reactor, the side port configured to supply an additional gas-phase mixture into the fluidized-bed reactor.

10. The system of claim 1 , wherein the energy source is external to the fluidized-bed reactor.

11. The system of claim 1 , wherein the fluidized-bed reactor is configured to modify a crystal structure of at least some of the carbon nano-particulates.

12. The system of claim 1 , wherein the fluidized-bed reactor is configured to chemically alter one or more exposed surfaces of at least some of the carbon nano-particulates.

13. The system of claim 1 , wherein the energy source is configured to generate the plasma-phase mixture in either a thermal equilibrium state or a non-thermal equilibrium state in response to a control signal.

14. The system of claim 13 , wherein the thermal equilibrium state is configured to control a plurality of energetic properties associated with one or more of the plasma-phase mixture or the gas-phase mixture.

15. The system of claim 14 , wherein the plurality of energetic properties includes an energy transfer rate between the plasma-phase mixture and the gas-phase mixture.

16. The system of claim 1 , wherein the fluidized-bed reactor is configured to homogenize at least some of the plurality of carbon nano-particulates in the powder.

17. The system of claim 1 , wherein the fluidized-bed reactor is configured to control a residence time associated with the matching network.

18. The system of claim 1 , wherein the plurality of carbon nano-particulates includes one or more non-hollow carbon spherical (NHCS) particles.

Assignees

• Lyten Inc

Inventors

• Nicole Jacques F
• Piotrowicz Pawel A
• Stowell Michael W

Classifications

• B01J2219/0894

  Processes carried out in the presence of a plasma · CPC title

• B01J2208/06

  Details of tube reactors containing solid particles · CPC title

• B01J2208/00893

  Feeding means for the reactants · CPC title

• B01J2208/00769

  Details of feeding or discharging · CPC title

• B01J2208/00539

  Pressure · CPC title