Microwave reactor system enclosing a self-igniting plasma

Patent metadata

Field	Value
Publication number	US-12281013-B2
Application number	US-202017008401-A
Country	US
Kind code	B2
Filing date	Aug 31, 2020
Priority date	Oct 6, 2016
Publication date	Apr 22, 2025
Grant date	Apr 22, 2025

Abstract

This disclosure provides a reactor system that includes a microwave energy source that generates a microwave energy, a field-enhancing waveguide (FEWG) coupled to the microwave source. The FEWG includes a field-enhancing zone having a cross-sectional area that decreases along a length of the FEWG. The field-enhancing zone includes a supply gas inlet that receives a supply gas, a reaction zone that generates a plasma in response to excitation of the supply gas by the microwave energy, a process inlet that injects a raw material into the reaction zone, and a constricted region that retains a portion of the plasma and combines the plasma and the raw material in response to the microwave energy within the reaction zone. An expansion chamber is in fluid communication with the constricted region facilitates expansion of the plasma. An outlet outputs a plurality of carbon-inclusive particles derived from the expanded plasma and the raw material.

First claim

What is claimed is:

1. A reactor system comprising:
a microwave energy source configured to generate a microwave energy;
a field-enhancing waveguide (FEWG) coupled to the microwave energy source, the FEWG including a field-enhancing zone having a cross-sectional area that decreases along a length of the FEWG, the field-enhancing zone comprising:
a supply gas inlet configured to receive a supply gas;
a reaction zone configured to generate a plasma in response to excitation of the supply gas by the microwave energy;
a process inlet configured to inject a raw material into the reaction zone; and
a constricted region configured to retain at least some of the generated plasma within the reaction zone, the constricted region further configured to combine the plasma and the raw material in response to microwave energy within the constricted region;

an expansion chamber in fluid communication with the constricted region and configured to expand the plasma; and
an outlet configured to output a plurality of carbon-inclusive particles derived from the expanded plasma and the raw material.

2. The reactor system of claim 1 , wherein the microwave energy is pulsed according to a pulse frequency.

3. The reactor system of claim 1 , wherein the field-enhancing zone is configured to concentrate the microwave energy in the constricted region.

4. The reactor system of claim 1 , wherein the FEWG further comprises a controller configured to adjust one or more of an electron density, an electron temperature, or a gas temperature within the FEWG.

5. The reactor system of claim 1 , wherein the FEWG is configured to self- nucleate the carbon-inclusive particles.

6. The reactor system of claim 1 , wherein the carbon-inclusive particles include graphene platelets.

7. The reactor system of claim 1 , further comprising one or more energy sources configured to generate a thermal energy.

8. The reactor system of claim 7 , wherein the thermal energy generated by the one or more energy sources is configured to disperse graphene platelets within each of the carbon-inclusive particles.

9. The reactor system of claim 1 , wherein the FEWG is configured to adjust a length of the plasma by selectively flowing one or more precursors through the field-enhancing zone.

10. The reactor system of claim 1 , wherein the constricted region is configured to concentrate the microwave energy in conjunction with the combining of the plasma and the raw material.

11. The reactor system of claim 10 , wherein the concentrated microwave energy is configured to ignite the plasma.

12. The reactor system of claim 1 , further comprising a pair of electrodes positioned on opposite sides of the FEWG and proximate to the reaction zone, the pair of electrodes configured to generate an electric field through which the plasma and the raw material are further combined.

13. The reactor system of claim 12 , wherein a degree of concentration of the microwave energy is based on a magnitude of the electric field generated by the pair of electrodes.

14. The reactor system of claim 13 , wherein the increase in the electric field strength is configured to cause a self-ignition of the plasma by combining any one or more of the supply gas or the raw material.

15. The reactor system of claim 1 , wherein microwave energy source is configured to adjust a pulsing frequency of the microwave energy.

16. The reactor system of claim 1 , wherein the raw material is configured to be converted into the carbon-inclusive particles in the expansion chamber.

17. The reactor system of claim 1 , wherein the raw material further comprises any one or more of carbonaceous particles, colloidal dispersions, or a plurality of solid particles.

18. The reactor system of claim 1 , wherein the constricted region further comprises an opening connecting the FEWG to the expansion chamber.

19. The reactor system of claim 18 , wherein the opening has a defined shape including any one or more of a rectangle, a square, or an ellipse.

20. The reactor system of claim 19 , wherein a density of the plasma is based at least in part on the defined shape of the opening.

21. The reactor system of claim 19 , wherein a homogeneity of plasma radicals within the plasma is based at least in part on the defined shape of the opening.

22. The reactor system of claim 21 , wherein the homogeneity of the plasma radicals within the plasma is configured to alter a density of the carbon-inclusive particles.

23. The reactor system of claim 18 , wherein the opening is configured to separate the plasma from one or more surfaces of the expansion chamber.

Assignees

• Lyten Inc

Inventors

• Tanner David
• Cook Daniel
• Anzelmo Bryce H
• Kalluri Ranjeeth
• Stowell Michael W

Classifications

• B01J2219/0886

  Gas-solid · CPC title

• B01J2219/1248

  Features relating to the microwave cavity · CPC title

• B01J2219/1209

  Features relating to the reactor or vessel · CPC title

• B01D46/00

  Filters or filtering processes specially modified for separating dispersed particles from gases or vapours (filtering elements B01D24/00-B01D35/00; filtering material B01D39/00; their regeneration outside the filters B01D41/00) · CPC title

• B01J2219/1296

  Multiple sources · CPC title