Influence of the Shroud Gas Injection Configuration on the Characteristics of a DC Non-transferred Arc Plasma Torch

The characteristics of the plasma jet emanating from a dc non-transferred plasma torch is affected by many factors including arc current, type of gas, gas flow rate, gas injection configuration and torch geometry. The present work focuses on experimental investigation of the influence of shroud gas injection configuration on the I–V characteristics and electro-thermal efficiency of a dc non-transferred plasma torch operated in nitrogen at atmospheric pressure. The plasma gas is injected into the torch axially and shroud gas is injected through three different nozzles such as normal, sheath and twisted nozzles. The effects of flow rates of plasma/axial gas and arc current on I–V characteristics and electro-thermal efficiency of the torch holding different nozzles are investigated. The I–V characteristics and electro-thermal efficiency of the torch are found to be strongly influenced by the shroud gas injection configuration. The effect of arc current on arc voltage decreases with increasing the axial gas flow rate. At higher axial gas flow rate (>?45 lpm), the I–V characteristics of the plasma torch are similar irrespective of the nozzle used. The variation of electro-thermal efficiency with arc current is almost similar to that of arc voltage with arc current. As expected, the electro-thermal efficiency is increased when the axial gas flow rate is increased and at higher axial gas flow rate, it is not influenced by the arc current and shroud gas configuration. The plasma torch with normal nozzle may be better in the range of operating conditions used in this study.     

Design and Characteristics of a Laminar Plasma Torch for Materials Processing

Thermal plasma jets have been widely used in various materials processing techniques. However, the conventional thermal plasma torches usually generate turbulent plasma jets with the disadvantages of high axial temperature gradient, a short jet length and difficulties in the process control relatively, limiting its applications to materials processing. Therefore, this paper proposes a new laminar plasma torch (LPT) working with pure nitrogen to generate laminar plasma jet (LPJ). Its design and structural characteristics, e.g. segmented anode, axial gas injection, parallel water cooling structure, etc., are detailed to ensure the stability, the favorable temperature and velocity distribution of the generated LPJ. Experiments on the characteristics of the LPT showed that the generated LPJ possessed high specific enthalpy (ranging between 10 and 90 kJ/g), long jet length (maximum length: 480 mm) and low axial temperature gradient, and its output power a current and the gas flow rate. In addition, the thermal efficiency of the LPT was experimentally determined to be ranging between 25 and 45 %. Furthermore, experiment and simulation on the application of the LPJ for surface quenching verified the even radial temperature distribution of the plasma jet and high heat flux density brought to the surface.     

Thermal Plasma Synthesis of Zirconia Powder and Preparation of Premixed Ca-Doped Zirconia

A novel study about the synthesis of zirconia and calcia-stabilized zirconia powders were carried out by DC thermal plasma starting from cheap precursors as the carbonates. Different operational parameters were investigated to explore the effects of the process conditions, such as the plasma torch power and the gas flow rate on the composition and the morphology of the powders. The products phase changes from a metastable tetragonal to monoclinic/tetragonal mixture. Basically a main tetragonal phase was obtained at low torch power (7 kW) while the amount of monoclinic phase linearly rises with the power, up to 66 wt% at 26 kW of plasma power and high gas flow rate. The gas flow rate also affects the shape and the size of the powder, where high values reduce powder aggregation and enhance the spherical shape. The best results were achieved at 22 kW of plasma power and high gas flow rate, with powders of roundness about 79% and a wide particle size distribution. Adding the calcium carbonate to the zirconium carbonate (corresponding to 8 wt% CaO in the final mixture), the plasma treatment mainly produces a tetragonal phase zirconia, that at 1400 °C in furnace changes in a stable cubic phase. These powders could be made suitable for further industrial applications after proper treatments.

     

Arc-Enhanced Plasma Machining Technology for High Efficiency Machining of Silicon Carbide

Atmosphere plasma etching methods have been demonstrated efficient in the etching of fused silica or ULE. However, because of the high chemical stability of silicon carbide (SiC), the conventional plasma etching methods seem incapable of obtaining a high material removal rate (MRR). We have found that MRR will be significantly improved while the electric spark appears between the plasma and the SiC surface. As a result, a new plasma source is designed to generate stable arc at the surface. Due to the generation of arc, the MRR of 0.35 mm³/min is obtained, about 10 times as high as the conventional method. In this paper, the removal characteristics and the thermal effect of this method are presented. MRR and the surface temperature are investigated in dependence on plasma parameters: RF power, travel speed of plasma source, SF₆ gas flow and O₂ gas flow. Due to the negligible thermal effect, the surface figuring can be achieved using the conventional dwell time method. The shape error of a flat SiC surface is corrected, verifying the figuring capability and the effectiveness of this method.     

Direct Measurement of the Gas Entrainment Into a Turbulent Thermal Plasma Jet

An experimental study is conducted to investigate the entrainment characteristics of a turbulent thermal plasma jet issuing from a DC arc plasma torch operating at atmospheric pressure. The mass flow rate of the ambient gas entrained into the turbulent plasma jet is directly measured by use of the so-called “porous-wall chamber” technique. It is shown that a large amount of ambient gas is entrained into the turbulent plasma jet. With the increase of the gas mass flow rate at the plasma jet inlet or the plasma torch exit, the mass flow rate of entrained ambient gas almost linearly increases but its ratio to the jet-inlet mass flow rate decreases. The mass flow rate of the entrained gas increases with the increase of the arc current or jet length. It is also found that using different ways to inject the plasma-forming gas into the plasma torch affects the entrainment rate of the turbulent plasma jet. The entrainment rate expression established previously by Ricou and Spalding (J. Fluid Mech. 11: 21, 1961) for the turbulent isothermal jets has been used to correlate the experimental data of the entrainment rates of the turbulent thermal plasma jet, and the entrainment coefficient in the entrainment rate expression is found to be in range from 0.40 to 0.47 for the turbulent thermal plasma jet under study.     

Analytical characteristics of an optimized miniature inductively-coupled plasma source for atomic emission spectrometry

The inside dimensions of a miniature (13 mm i.d.) inductively-coupled plasma (i.c.p.) torch were optimized in an attempt to reduce further the r.f. power and argon gas required to sustain an i.c.p. As found earlier with a conventional-sized (18 mm i.d.) torch, the annular spacing between the plasma (intermediate) and coolant (outer) tube was shown to be the most critical design parameter. However, the optimized miniature i.c.p. could not necessarily be operated at lower r.f. power and argon flow rate than the optimized 18-mm torch or at lower argon flow rate than the original 13-mm torch. Moreover, although the detection limits and working-curve linearity of the optimized mini-i.c.p. were comparable to those of a conventional-sized torch, the errors caused by classical vaporization interferents were somewhat greater.     

MPT-AES测定奶粉中的Ca和Fe

用微波等离子体(MPT)为激发光源,氩气为等离子体工作气体,用气动雾化进样,采用标准曲线法研究了微波等离子体炬原子发射光谱法(MPT-AES)测定奶粉中Ca、Fe的方法。详细考察了溶液中HCl浓度、HNO3浓度、微波前向功率、载气流量、工作气流量等实验参数对测定的影响,同时考察了共存元素钠、镁、锌对钙和铁发射强度的影响。     

Thermal stability and flammability of polyurethane foams chemically reinforced with POSS

Manganese ferrite nanopowder was prepared by a new solvothermal method, using 1,2 propanediol as solvent and KOH as precipitant. The as-synthesized powder, by solvothermal treatment in autoclave at 195 °C, for 12 h, consisted of fine manganese ferrite nanoparticles. The further thermal treatment of the initial manganese ferrite powder to higher temperature resulted in manganese ferrite decomposition due to Mn(II) oxidation to Mn(III), as observed by X-ray diffraction. FT-IR spectroscopy has evidenced that the oxidation takes place even at 400 °C. The oxidation of Mn(II) to Mn(III) was studied by TG/DSC simultaneous thermal analysis. It was shown that Mn(II) oxidation takes place in a very small extent up to 400 °C. The main oxidation step occurs around 600 °C, when a clear mass gain is registered on TG curve, associated with a sharp exothermic effect on DSC curve. The exothermic effect is smaller in case of the powder annealed at 400 °C, confirming the superficial oxidation of Mn(II) up to 400 °C. In order to avoid Mn(II) oxidation, the powder obtained at 400 °C was further annealed at 800 °C in argon atmosphere, without degassing, when manganese ferrite MnFe₂O₄ was obtained as major crystalline phase (69 %). All manganese ferrite powders showed a superparamagnetic behavior, with maximum magnetization of 51 emu g^?1 in case of the as-synthesized powder, characteristic of magnetic ferrite nanopowders.     

Synthesis of Ozone at Atmospheric Pressure by a Quenched Induction-Coupled Plasma Torch

The technical feasibility of using an induction-coupled plasma (ICP) torch to synthesize ozone at atmospheric pressure is explored. Ozone concentrations up to ~250 ppm were achieved using a thermal plasma reactor system based on an ICP torch operating at 2.5 MHz and ~11 kVA with an argon/oxygen mixture as the plasma-forming gas. The corresponding production rate and yield were ~20 g ozone/hr and ~2g ozone/kWh, respectively. A gaseous oxygen quench formed ozone by rapid mixing of molecular oxygen with atomic oxygen produced by the torch. The ozone concentration in the reaction chamber was measured by Fourier Transform infrared (FTIR) spectroscopy over a wide range of experimental conditions and configurations. The geometry of the quench gas flow, the quench flow velocity, and the quench flow rate played important roles in determining the ozone concentration. The ozone concentration was sensitive to the torch RF power, but was insensitive to the torch gas flow rates. These observations are interpreted within the framework of a simple model of ozone synthesis.     

The modes of combustion of copper nanopowders

It was shown that the synthesis of Cu nanopowder by thermal decomposition afforded chemically purer (without oxides) and finer (specific surface value ～45 m2 g^?1) product than the synthesis by chemical reduction. The latter method leads to pyrophoric nanopowders containing detectable amounts of copper oxides.     

Carbon Blacks Produced by Thermal Plasma: the Influence of the Reactor Geometry on the Product Morphology

Carbon black (CB) nanopowders were obtained by plasma decomposition of methane at various flow rates using inductively coupled thermal plasma torch system of 35 kW. Nitrogen was also introduced in some experiments along with the methane. Using a cylindrical shape reactor the obtained powders were composed mainly of spherical particles, non-uniform in terms of particles size with diameters between 30 and 150 nm. The shape and size of this reactor resulted in the presence of recirculation areas enabling the formation of large CB particles and other secondary volatile compounds. Changing the reactor to a conical geometry resulted in the production of CB powders showing a crystalline and flake-like morphology made of sheets having 6–16 graphitic planes. The conical shape avoids the presence of recirculation areas and promotes the formation of a uniform powder morphology throughout the reactor.     

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     

Steam Plasma Methane Reforming for Hydrogen Production

Reactions of methane with water and CO₂ in thermal plasma generated in a special plasma torch with a water-stabilized arc were investigated. Steam plasma with very high enthalpy and low mass flow rate was produced in a dc arc discharge which was in direct contact with water vortex surrounding the arc column. Composition of produced gas, energy balance of the process and its efficiency were determined from measured data. The output H₂/CO ratio could be adjusted by a choice of feed rates of input reactants in the range 1.1–3.4. Depending on experimental conditions the conversion of methane was up to 99.5%, the selectivity of H₂ was up to 99.9%, and minimum energy needed for production of 1 mol of hydrogen was 158 kJ/mol. Effect of conditions on process characteristics was studied. Comparison of measured data with results of theoretical computations confirmed that the reforming process produces gas with composition which is close to the one obtained from the thermodynamic equilibrium calculations. Relations between process enthalpy, composition of produced syngas and process characteristics were determined both theoretically and experimentally.     

Effects of process parameters on ultrafine SiC synthesis using induction plasmas

A study is reported of the formation of ultrafine SiC powder through the reaction of elemental silicon and CH₄ in an induction plasma. The reaction route used involved in the first place the vaporization of a fine elemental silicon powder axially injected into the center of the discharge followed by the carburization reaction through the coinjection of CH₄. The powder obtained was composed of a mixture of α- and β-SiC with varying amounts of free carbon and free silicon. The particle size distribution was typically in the range of 40–60 nm with a corresponding specific surface area of 30–50 m²/g. A parametric study showed that the quality of the powder obtained varied with the plasma plate power and the position of the injection probe. The plasma gas composition employed was found to influence the proportions of α- and β-SiC in the synthesized SiC powder. With an Ar/N₂ mixture as the plasma gas, the ratio of the α to β phases was less than 1.0, whereas the ratio was greater than 1.5 when using a mixture of Ar/H₂ as plasma gas. The Si powder feed rate and the input C/Si molar ratio in the injected reactants significantly affected both the formation of the SiC and the free Si and free C content in the synthesized powder. Lining the cylindrical reactor wall with graphite resulted in improved conversion of Si to SiC. The weight fraction of the powder collected at different sections of the reactor system varied with the reactor operating conditions. The experimental results support the view that the formation mechanism for ultrafine SiC is dominated by the reaction of Si vapor with the thermal decomposition products of CH₄.     

Steam Torch Plasma Modelling

Numerical modelling of physical properties and processes in an electric arc stabilized by a water vortex (steam torch) has been summarized in this review paper. One-fluid MHD equations are numerically solved for an axisymmetric thermal plasma flow inside a discharge chamber of the steam plasma torch. The steady state solution results are discussed for the range of currents 300–600 A with relatively low steam flow rate of about 0.3 g s^?1. The maximum obtained velocities and temperatures—8500 m s^?1, 26,300 K, are reported at the centre of the nozzle exit for 600 A. The evaporation of water, i.e. mass flow rate of steam, was predicted from a comparison between the present simulation and experiments. The generated plasma is mildly compressible (M < 0.7) with the inertial forces overwhelming the magnetic, viscous, centrifugal and Coriolis forces with the factor of 10³. Our calculations showed that the most significant processes determining properties of the arc are the balance of the Joule heat with radiation and radial conduction losses from the arc. Rotation of plasma column due to the tangential velocity component has a negligible effect on the overall arc performance, however, the rotation of water induces fluctuations in the arc and in the plasma jet with characteristic frequency which is related to the frequency of rotation of water. Reabsorption of radiation occurs at the radial position higher than 2.5 mm from the arc axis. The amount of reabsorbed radiation is between 17 and 28%. LTE conditions are satisfied in the arc column with the 2 mm radius. Comparison between the present simulations and experiments shows good agreement with the current–voltage characteristics, radial velocity and temperature profiles, as well as with the other related numerical simulation.     

Tungsten Carbide and Vanadium Carbide Nanopowders Synthesis in DC Plasma Reactor

Air–methane and nitrogen–hydrogen DC thermal plasma confined flows were used to synthesize tungsten carbide and vanadium carbide nanopowders. The influence of input process parameters such as C/W and C/V molar ratio, plasma jet chemical composition, plasma jet enthalpy, and reactants flow rates on the average nanoparticle size, chemical and crystallographic phase compositions were investigated. During post heat treatment, the synthesized MeC_1?x nanopowders were fully carburized to monocarbides WC and VC with particles size less than 80 and 40 nm correspondently.     

Synthesis and Photoproperties of Silicon Phthalocyanines and Silicon Naphthalocyanines

Silicon phthalocyanines and silicon naphthalocyanines, which are two derivatives in the family of hematoporphyrin, have been synthesized to assess their potential as photosensitizers for photodynamic therapy. For these complexes the red shift of their Q-band maximum absorption tends to depend on the nature of the axial substituent. The bimolecular rate coefficients for the interacting between photosensitizer, either SiNC or SiPC, and generated singlet molecular oxygen were determined from the time-resolved emission spectrum of singlet oxygen at 1.27 μm. On the basis of these data the electron-transfer quenching mechanism is discussed in relation to the Marcus model.     

Quenching Experiment Study on Thermal Plasma Pyrolysis Process of Coal Tar

Quenching is a key approach to obtain high acetylene yield in the process of coal tar pyrolysis to produce acetylene in a thermal plasma reactor due to the thermodynamic characteristics of acetylene. Experiments of coal tar pyrolysis were carried out in a lab-scale H₂/Ar plasma reactor under various quenching conditions. Meanwhile, thermodynamic analysis was performed to assist the optimization of quenching temperature and the maximization of acetylene yield. As quenching media in the experiments, hydrogen, argon, methane, and water were used separately to study the influence of quenching process on acetylene yield and specific energy requirement. The experimental results indicate that the acetylene concentration in quenched product gas was significantly affected by quenching operation, and the acetylene yield was significantly affected by quenching medium flow rate. The acetylene yields of 24.6, 17.8, 44.9 and 23.6 wt% can be reached by using hydrogen, argon, methane, and water as quenching media, respectively. The specific energy requirement analysis indicates that process energy efficiency can be improved by a suitable quench operation.     

Silicon determination by inductively coupled plasma atomic emission spectrometry after generation of volatile silicon tetrafluoride

A method for the determination of silicon by inductively coupled plasma atomic emission spectrometry (ICP-AES) is described. The procedure is based on a discontinuous generation of volatile silicon tetrafluoride in concentrated sulphuric acid medium after injecting 125 μl of 0.1%, w/v sodium fluoride solution into 100 μl of the sample. The gaseous silicon tetrafluoride is fed directly into the ICP torch by a flow of 250 ml min⁻¹ Ar carrier gas. The calibration curve was linear up to at least 100 μg ml⁻¹ of Si(IV) and the absolute detection limit was 9.8 ng working with a solution volume of 100 μl. The relative standard deviation for six measurements of 10 μg ml⁻¹ of Si(IV) was 2.32%. The method was applied to the determination of silicon in water and iron ores.