In-flight Melting Behavior of Granulated Alkali-Free Raw Material in Induction Thermal Plasmas

A new in-flight glass melting technology with induction thermal plasmas was developed to reduce the energy consumption and the emissions of greenhouse gases for glass production. The effects of carrier gas on the in-flight melting behavior of granulated alkali-free raw material were investigated by various modern analyses. Results show that the particles have smooth spherical surface and compact structure after heat treatment. As the carrier gas flow rate increases, the vitrification degree decreases and the average diameter increases. Higher vitrification results in more shrinkage of particle. The carbonates in raw material decompose completely during in-flight melting. The highest volatilization of B₂O₃ is attributed to more heat transferred from plasmas to particles at the lowest carrier gas flow rate.     

Investigation of Electrode Phenomena in an Innovative Thermal Plasma Process for Glass Melting

A multi-phase alternating current (AC) arc has been applied to glass melting technology. The large volume discharge produced by a stable multi-phase AC arc is preferable to melt the granulated glass materials. The discharge behavior and the high-temperature region of the plasma can be controlled by the electrode configurations. In this study, the spatial characteristics of the arc discharge were examined by image analysis of high-speed camera. Results show arc existence area is related with electrode configuration. This study provides the useful information of efficient particle treatment in the preferred electrode configuration. However, the electrode erosion is one of the most considerable issues to be solved. The combination of high-speed video camera and band-pass filters was introduced to measure the electrode temperature to investigate the erosion mechanism of the multi-phase AC arc. The dynamic behavior of the electrode vapors in the arc was investigated by using the same high-speed camera system. Results show the tungsten electrode mainly evaporates at the anodic period during AC cycle.     

Study of Injection Angle and Carrier Gas Flow Rate Effects on Particles In-Flight Characteristics in Plasma Spray Process: Modeling and Experiments

This paper investigates the influence of particle injection angle on particle in-flight behaviors and characteristics at different primary and carrier gas flow rates through an integrated modeling and experimental approach. Particle in-flight status such as temperature, velocity, size and their distribution are analyzed to examine particle’s melting status before impact. Results from the experiments and numerical simulations both show that, when carrier gas flow rate is fixed, a small injection angle favors the particle melting and flattening. This behavior is independent of primary and secondary gas flow rates, spray distance and carrier gas flow rate. When both carrier gas flow and injection angle vary, a high carrier gas flow rate and a small injection angle are recommended for high particle temperature and velocity.     

Gas flow dynamics of an inductively coupled plasma discharge

Temperature and velocity distributions within a low power (0.5–0.75 kW) inductively coupled plasma discharge operating in argon have ben determined for various operating parameters including aerosol gas now rate, plasma gas flow rate, aerosol nozzle diameter, and input power level. All measurements were made without samples. The channel formed in the discharge by the aerosol gas now exhibits temperature and velocity characteristics which distinguishes it from the plasma core and wall regions. Maximum plasma temperature of 8700 ± 300 K and channel gas velocity of 120 $\text{m}\text{s}$ were found.     

非平衡等离子体放电模式及反应器结构对氨气分解制氢的影响

在常压下研究了不同等离子体放电模式及反应器结构对氨分解制氢反应的影响.实验中调节反应器结构分别产生了介质阻挡放电和交流弧放电两种放电模式.通过对两种放电模式的放电图像、电压-电流波形和氨分解过程中等离子体区活性物种的发射光谱(OES)研究发现,与介质阻挡放电相比,交流弧放电为局部强放电,具有更高的电源效率和电子密度.因此,在介质阻挡放电中氨气分子大部分通过生成电子激发态物种NH3*,再与载能电子碰撞断裂N―H键进行氨分解反应;而在交流弧放电中载能电子具有更高的平均电子能量,可直接断裂氨气分子的N―H键生成NH2和NH等高活性物种,促进氨分解反应的进行.结果表明,交流弧放电的氨分解效果要明显优于介质阻挡放电.在交流弧放电模式下不同类型反应器对氨气分解转化率由高到低的顺序为:管-管管-板针-板板-板.在输入功率为30 W,气隙间距为6 mm时,管-管交流弧放电的氨气转化率达到60%左右,而板-板介质阻挡放电的氨气转化率仅为4%.     

The Dependence of Gliding Arc Gas Discharge Characteristics on Reactor Geometrical Configuration

The dependence of gliding arc gas discharge characteristics, including gas flow field, arc column motion and volatile organic compounds (VOCs) decomposition performance, on reactor configuration parameters was investigated based on numerical simulation and laboratory experimental findings. For a given supply voltage (10 kV) and a certain nozzle outlet diameter (1.5 mm), increasing the electrodes gap (1–4 mm) or decreasing vertical distance between electrode throat and nozzle outlet (25–10 mm) will increase the gas flow rate through the electrode throat, the gas velocity in the plasma region, the arc column velocity, the maximum attainable position of the arc column and the electrical power consumption, also, higher VOCs decomposition rate and lower specific energy requirement are observed according to the n-butane and toluene decomposition experiments.     

Heat Generation and Particle Injection in a Thermal Plasma Torch

The operation of plasma guns used for plasma spraying involves a continuous movement of the anode arc root. The resulting fluctuations of voltage and thermal energy input introduce an undesirable element in the spray process. This paper deals with the effects of these arc instabilities on the plasma jet, and the behavior of particles injected in the flow. The first part refers to the formation of the plasma jet. Measurements show that the static behavior of the arc depends strongly upon the plasma-forming gas mixture, especially the mass flow rate, of the heavy gas, injection mode, nozzle diameter, and arc current. These parameters control the electric field in the arc column, the arc length, its stability, and the gas velocity and temperature. The dynamic behavior of the arc is examined to determine how the tempeature and velocity of the plasma gas vary with voltage variations. Relationships between the gas velocity at the nozzle exit and the lifetime of the arc roots, and the independent operating parameters of the gun can be established from a dimensional analysis. The second part discusses the interaction between the plasma jet and the particles injected into the flow. The parameters controlling particle injection and trajectory are examined to determine how injection velocity must vary with particle size and density to achieve a given trajectory. The effect of the transverse injection of the powder carrier gas is investigated using a 3-D computational fluid dynamics code. Finally, the effect of the jet fluctuations on particle trajectory is studied under the assumption that the jet velocity follows the voltage variation. The result is a continuous variation of the particle spray jet position in the flow. Experimental observations confirm the model predictions.     

Kinetic Modeling of Plasma Methane Conversion Using Gliding Arc

Plasma methane (CH4) conversion in gliding arc discharge was examined. The result data of experiments regarding the performance of gliding arc discharge were presented in this paper. A simulation which is consisted some chemical kinetic mechanisms has been provided to analyze and describe the plasma process. The effect of total gas flow rate and input frequency refers to power consumption have been studied to evaluate the performance of gliding arc plasma system and the reaction mechanism of decomposition.Experiment results indicated that the maximum conversion of CH4 reached 50% at the total gas flow rate of 1 L/min. The plasma reaction was occurred at the atmospheric pressure and the main products were C (solid), hydrogen, and acetylene (C2H2). The plasma reaction of methane conversion was exothermic reaction which increased the product stream temperature around 30～50℃.     

Dry Reforming of Methane with Carbon Dioxide Using Pulsed DC Arc Plasma at Atmospheric Pressure

Dry reforming of CH₄ with CO₂ to produce syngas was investigated in a plasma reactor without catalysts at atmospheric pressure. The reactants passed through the plasma zone and reacted in milliseconds with high conversions and selectivity due to the localized high temperature. The results showed that both conversions and selectivity were higher when using a DC arc discharge than using a pulsed DC arc. Increasing the input energy density promoted the conversions of reactants. At an input power of 204 W, the conversions of CO₂ and CH₄ reached 99.3 and 99.6%, respectively, and the selectivity to products was almost 100%, where the molar ratio of CO₂/CH₄ was 1 with the reactants flow rate of 100 ml/min. Very little coke was formed during the course of reaction. Key parameters such as the pulse frequency, the input power and the total feed flow rate were studied to find the optimum operating condition.     

High Speed Video Camera and Electrical Signal Analyses of Arcs Behavior in a 3-Phase AC Arc Plasma Torch

A 3-phase AC plasma torch has been developed and aims at overcoming some limits of the classical DC torches in terms of efficiency, cost and reliability. However, the arc behavior in 3-phase plasma torch remains poorly explored. This paper is dedicated to the high speed video camera at 100,000 frames per second and electrical signal analyses of arcs behavior in a 3-phase AC arc plasma torch. First, a reference case at 150 A, in nitrogen as working gas, has been deeply analyzed. Afterwards, a parametric study based on current and inter-electrode gap has been carried out. Results show that only one arc can exist at a given time and arcs rotate by switching from a pair of electrodes to another one, following the maximal electrical gap potential. However, a particular “abnormal” arc behavior was sometimes observed. Indeed, the arc motion within the inter-electrode gap increases the heat exchange and stabilizes the 3-phase discharge whereas the system is unbalanced when the arc is in the periphery. The analysis highlights that the arc motion is strongly influenced by the electrode jet velocity and repulsive Lorentz forces. The parametric study shows that the current increases both jet velocity and arc discharge stability. Elsewhere, the increase of the inter-electrode gap can also stabilizes the electrical 3-phase arc discharge. Furthermore, the correlation between arc motion and current waveform is highlighted. This work is likely to open the way toward a better understanding of 3-phase discharges in the perspective of their further optimization.     

Influence of Duty Cycle on Ozone Generation and Discharge Using Volume Dielectric Barrier Discharge

The influence of duty cycle on ozone generation and discharge characteristics was investigated experimentally using volume dielectric barrier discharge in both synthetic air and pure oxygen at atmospheric pressure. The discharge was driven by an amplitude-modulated AC high voltage–power supply producing T_ON (a single AC cycle) and T_OFF periods with a widely variable duty cycle. The experimental results show that the energy delivered to the discharge during each AC cycle remains roughly constant and is independent of feed gas, duty cycle and T_OFF. Both average discharge power and ozone concentration show an initial linear increase with duty cycle, and deviate gradually from linearity owing to an increase in gas temperature at higher duty cycles. Nevertheless, ozone yield remains nearly constant (45.7 ± 3.5 g/kWh in synthetic air and 94.7 ± 3.1 g/kWh in pure oxygen) over a wide range of applied duty cycles (0.02–1). This property can be conveniently employed to develop a unique ozone generator with a widely adjustable ozone concentration and simultaneously a constant ozone yield. Additionally, the discharges in synthetic air and pure oxygen have similar electrical characteristics; however, there are observable differences in apparent luminosity, which is weak and white-toned for synthetic air discharge, and bright and blue-toned for pure oxygen discharge.     

Direct Non-oxidative Methane Conversion by Non-thermal Plasma: Experimental Study

The direct non-oxidative conversion of methane to higher hydrocarbons in non-thermal plasma, namely dielectric barrier discharge and corona discharge, has been investigated experimentally at atmospheric pressure. In dielectric barrier discharge, the methane is mainly converted to ethane and propane with small amounts of unsaturated and higher hydrocarbons. While in corona discharge, methane was activated mainly to acetylene with small amount of other higher hydrocarbons. Decreasing the gas flow or increasing power input will improve the methane conversion and product yields. It is found that the methane conversion and main product yield against the input specific energy were special functions in both dielectric barrier discharge and corona discharge, independent of the reactor size, and whether fixing flow rate or power input and changing the power input or flow rate. The corona discharge is a promising alternative method for methane conversion to produce acetylene and hydrogen at low temperature.     

Particle Injection in Direct Current Air Plasma Spray: Salient Observations and Optimization Strategies

External injection of high-melting point low thermal conductivity ceramics orthogonal to a typical direct current thermal plasma jet plays a vital role in determining the in-flight state of the particles and the process downstream. The interactions between low density ceramic particles and high temperature plasma jet is quite complex, which influences the spray process and associated deposition. Detailed in-flight particle diagnostics as well as spray stream visualization have significantly enhanced our capability to diagnose and control the process. In this paper we present some salient observations on the role of key variables on particle injection. A number of experiments were conducted using a 7MB torch (Sulzer Metco, Westbury, NY) with both Ar–H₂ and N₂–H₂ plasma gases, where the carrier gas flow to inject Yttria Stabilized Zirconia (YSZ) was varied systematically and the resulting in-flight particle state was captured using an array of particle and spray stream sensors arranged in a 3D set-up. A notable observation is the existence of a “sweet-spot” in the plasma jet where the particle temperatures and velocities achieved a maximum. This sweet-spot can be characterized by the plume position (location of centroid of the spray stream) rather than carrier gas flow rate and is independent of primary gas flows and other process/material conditions. This result suggests a possible approach to optimize particle injection independent of plasma-forming-torch-parameters. Controlling particle injection at this sweet-spot has shown to benefit the overall process efficiency (in terms of melting) and process reliability (both in-flight measurement and coating build-up) with concomitant application benefits.     

Synthesis Gas Production from CO2-Containing Natural Gas by Combined Steam Reforming and Partial Oxidation in an AC Gliding Arc Discharge

In this study, a technique of combining steam reforming with partial oxidation of CO₂-containing natural gas in a gliding arc discharge plasma was investigated. The effects of several operating parameters including: hydrocarbons (HCs)/O₂ feed molar ratio; input voltage; input frequency; and electrode gap distance; on reactant conversions, product selectivities and yields, and power consumptions were examined. The results showed an increase in either methane (CH₄) conversion or synthesis gas yield with increasing input voltage and electrode gap distance, whereas the opposite trends were observed with increasing HCs/O₂ feed molar ratio and input frequency. The optimum conditions were found at a HCs/O₂ feed molar ratio of 2/1, an input voltage of 14.5?kV, an input frequency of 300?Hz, and an electrode gap distance of 6?mm, providing high CH₄ and O₂ conversions with high synthesis gas selectivity and relatively low power consumptions, as compared with the other processes (sole natural gas reforming, natural gas reforming with steam, and combined natural gas reforming with partial oxidation).     

Hydrogen Isotope Exchange Reactions in an Atmospheric Pressure Discharge Utilizing Water as Carrier Gas

Allowing water/hydrogen or water/hydrogen/He gas mixture to flow through micro- hollow type of electrodes and applying 60 Hz AC power between the electrodes made it possible to sustain large area and atmospheric pressure discharge. The electrode assembly was constructed by sandwiching a dielectric spacer with two thin metal sheets and boring an array of micro holes through them. Another variation of the assembly was prepared by stacking thin metallic sheets so that the stack functions as an electrode through which the gas mixture flows for generating dielectric barrier discharge. A large volume of the gas mixture, while producing plasma, underwent instantaneous hydrogen isotope exchange reactions between H₂O and D₂O or between D₂O and H₂ gas molecules. The efficiency of the atmospheric pressure discharge was assessed by measuring the extent of the exchange reactions at a given flow rate of the gas mixture.     

Laser Doppler anemometry under plasma conditions. Part II. Measurements in an inductively coupled r.f. plasma

Laser Doppler anemometry is used for the measurements of the plasma and particle velocity profiles in the coil region of an inductively coupled r.f. plasma. Results are reported for a 50 mm i.d. induction plasma torch operated at atmospheric pressure with argon as the plasma gas. The oscillator frequency is 3 MHz and the plate power is varied between 4.6 and 10.5 kW. Plasma velocity measurements are obtained using a fine carbon powder as a tracer. Measurements are also given for larger silicon particles ( ) centrally injected into the discharge under different operating conditions.Nomenclature d _p particle diameter - P ₀ plasma power - Q ₁ powder carrier gas flow rate - Q ₂ plasma gas flow rate - Q ₃ sheath gas flow rate - r distance in the radial direction - V axial plasma velocity - V _p axial particle velocity - Z distance in the axial direction - standard deviation     

Effects of Nozzle Length and Process Parameters on Highly Constricted Oxygen Plasma Cutting Arc

The influence of nozzle length and two process parameters (arc current, mass flow rate) on the plasma cutting arc is investigated. Modeling results show that nozzle length and these two process parameters have essential effects on plasma arc characteristics. Long nozzle torch can provide high velocity plasma jet with high heat flux. Both arc voltage and chamber pressure increase with the nozzle length. High arc current increases plasma velocity and temperature, enhances heat flux and augments chamber pressure and thus, the shock wave. Strong mass flow has pinch effect on plasma arc inside the torch, enhances the arc voltage and power, therefore increases plasma velocity, temperature and heat flux.     

Plasma Spray Process Operating Parameters Optimization Based on Artificial Intelligence

During plasma spray process, many intrinsic operating parameters allow tailoring in-flight particle characteristics (temperature and velocity) by controlling the plasma jet properties, thus affecting the final coating characteristics. Among them, plasma flow mass enthalpy, flow thermal conductivity, momentum density, etc. result from the selection of extrinsic operating parameters such as the plasma torch nozzle geometry, the composition and flow rate of plasma forming gases, the arc current intensity, beside the coupled relationships between those operating parameters make difficult in a full prediction of their effects on coating properties. Moreover, temporal fluctuations (anode wear for example) require “real time” corrections to maintain particle characteristic to targeted values. An expert system is built to optimize and control some of the main extrinsic operating parameters. This expert system includes two parts: (1) an artificial neural network (ANN) which predicts an extrinsic operating window and (2) a fuzzy logic controller (FLC) to control it. The paper details the general architecture of the system, discusses its limits and the typical characteristic times. The result shows that ANN can predict the characteristics of particles in-flight from coating porosity within maximal error 3 and 2 % in temperature and velocity respectively. And ANN also can predict the operating parameters from in-flight particle characteristics with maximal error 2.34, 4.80 and 8.66 % in current intensity, argon flow rate, and hydrogen flow rate respectively.     

Chemical and Physical Characteristics of Pulsed Electrical Discharge Within Gas Bubbles in Aqueous Solutions

The chemical and physical characteristics of pulsed electrical discharge within gas bubbles immersed in an aqueous solution were investigated using a reactor with long protrusion length high voltage needle electrodes. Argon gas was introduced at the base of the needle electrode causing gas bubbles to flow upwards in contact with the needle. The effects of needle protrusion length were evaluated by using 2, 4, and 6 cm length needles under a wide range of power input (3–78 W). No significant differences in chemical or electrical characteristics were found among the different protrusion lengths. H₂ and H₂O₂ generation rates were proportional to input power and the energy yield efficiency for these species was not affected dramatically by input power. The results of discharge within bubbles in aqueous solution were also compared with those for direct liquid phase discharge and gas phase discharge above the liquid surface.